VW Passat b6 Electrical System Diagram

Service
Workshop Manual
Passat 2006 ➤
Passat Variant 2006 ➤
Electrical system
Edition 10.2013
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
27 - Starter, current supply, CCS
90 - Gauges, instruments
92 - Windscreen wash/wipe system
94 - Lights, bulbs, switches - exterior
96 - Lights, bulbs, switches - interior
97 - Wiring
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2015 Volkswagen AG, Wolfsburg K0059020020

Passat 2006 ➤ , Passat Variant 2006 ➤
Electrical system - Edition 10.2013
Contents
27 - Starter, current supply, CCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Fundamentals for batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Types of battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Warning notices and safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.4 Battery terminal connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Checking battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Charging battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4 Disconnecting and reconnecting battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.1 Disconnecting and connecting battery, vehicles with battery in engine compartment . . . . 4
4.2 Disconnecting and reconnecting battery, vehicles with additional battery in luggage
compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.3 Disconnecting and reconnecting battery, vehicles with battery in luggage compartment . . 8
5 Removing and installing battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.1 Petrol engine vehicles with battery installed in engine compartment . . . . . . . . . . . . . . . . . . 11
5.2 Diesel engine vehicles with battery installed in engine compartment . . . . . . . . . . . . . . . . 12
5.3 Vehicles with an additional battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.4 Vehicles with battery in luggage compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6 Specified torques: battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.1 Specified torques: battery in engine compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.2 Specified torques: additional battery/battery in luggage compartment . . . . . . . . . . . . . . . . 21
7 Pyrotechnic battery isolator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7.1 Fitting location overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7.2 Safety precautions when working on pyrotechnical battery isolator . . . . . . . . . . . . . . . . . . 23
7.3 Disposal of pyrotechnical battery isolation units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7.4 Removing and installing pyrotechnical battery isolator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8 Specified torques: pyrotechnic battery isolator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
8.1 Specified torques: main fuse box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
9 Jump start point with suppression filter C24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
9.1 Fitting location overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
9.2 Removing and installing jump start point with suppression filter C24 . . . . . . . . . . . . . . . . 27
10 Specified torques: jump start point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
11 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
11.1 Checking starter B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
11.2 Removing and installing starter, automatic gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
11.3 Removing and installing starter, dual clutch gearbox (DSG) . . . . . . . . . . . . . . . . . . . . . . . . 38
11.4 Removing and installing starter, manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
12 Specified torques: starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
13 Starter, vehicles with 1.8 l TSI engine and manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . 66
13.1 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
13.2 Removing and installing starter, vehicles with 1.8 l TSI engine and manual gearbox . . . . 67
14 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
14.1 Securing B+ (battery positive) wire to alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
14.2 Checking poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
14.3 Checking alternator C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
14.4 Alternator, 1.4 l TSI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
14.5 Alternator, 1.8 l TSI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
14.6 Alternator, 1.6 l injection engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
14.7 Alternator, 1.6 l FSI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
14.8 Alternator, 2.0 l FSI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
14.9 Alternator, 2.0 l FSI turbocharged engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Contents i
14.10 Alternator, 3.6 l FSI engine and 3.2 l injection engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
14.11 Alternator, 1.6 l TDI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
14.12 Alternator, 1.9 l and 2.0 l TDI engine (2 valves per cylinder) . . . . . . . . . . . . . . . . . . . . . . . . 112
14.13 Alternator, 2.0 l TDI engine (4 valves per cylinder) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
14.14 Alternator, 2.0 l TDI common rail injection engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
14.15 Removing and installing poly V-belt pulley on alternator . . . . . . . . . . . . . . . . . . . . . . . . . . 127
14.16 Voltage regulator for alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
15 Specified torques: alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
15.1 General specified torques for all vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
15.2 1.6 l injection engine and 2.0 l FSI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
15.3 2.0 l FSI turbocharged engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
15.4 3.6 l FSI engine and 3.2 l injection engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
15.5 1.9 l and 2.0 l TDI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
16 Cruise control system (CCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
16.1 Activating and deactivating cruise control system (CCS) . . . . . . . . . . . . . . . . . . . . . . . . . . 139
17 Adaptive cruise control (ACC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
17.1 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
17.2 Removing and installing adaptive cruise control button E357 . . . . . . . . . . . . . . . . . . . . . . 141
17.3 Removing and installing adaptive cruise control unit J428 . . . . . . . . . . . . . . . . . . . . . . . . 141
17.4 Calibrating adaptive cruise control sensor G550 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
17.5 Initialising adaptive cruise control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
90 - Gauges, instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

1 Dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
1.1 Adapting/renewing dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
1.2 Removing and installing dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
1.3 Dash panel insert final control diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
1.4 Description of back of dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
1.5 Pin assignment of connectors on dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
1.6 Warning lamp symbols in dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
2 Service interval display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
2.1 Resetting service interval display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
92 - Windscreen wash/wipe system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

1 Windscreen wiper system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
1.1 Deactivating APP function of wiper motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
1.2 Removing and installing windscreen wiper system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
1.3 Removing and installing wiper arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
1.4 Adjusting wiper blade park position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
1.5 Removing and installing aerodynamic wipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
1.6 Removing and installing rain and light sensor G397 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
2 Windscreen washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
2.1 Assembly overview - windscreen washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
2.2 Removing and installing washer fluid reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
2.3 Removing and installing washer pump V5 or windscreen and rear window washer pump V59
...................................................................... 168
2.4 Removing and installing windscreen washer fluid level sender G33 . . . . . . . . . . . . . . . . . . 169
2.5 Removing and installing windscreen washer system spray jets . . . . . . . . . . . . . . . . . . . . . . 169
2.6 Adjusting windscreen washer system spray jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
3 Rear window wiper system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
3.1 Assembly overview - rear window wiper system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
3.2 Removing rear window wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
3.3 Adjusting rear window wiper park position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
3.4 Removing and installing aerodynamic wipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
4 Rear window washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
ii Contents
4.1 Assembly overview - rear window washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

4.2 Renewing spray jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
4.3 Adjusting spray jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
5 Headlight washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
5.1 Assembly overview - headlight washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
5.2 Removing and installing headlight washer system pump V11 . . . . . . . . . . . . . . . . . . . . . . 180
5.3 Removing and installing pop-up cylinder with spray jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
5.4 Removing and installing spray jet assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
5.5 Adjusting spray jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
5.6 Bleeding headlight washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
5.7 Adapting headlight washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
6 Washer fluid line hose couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
6.1 Headlight washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
7 Hose repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
8 Specified torques: window wash/wipe system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
8.1 Specified torques for windscreen wash/wipe system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
8.2 Specified torques for rear window wash/wipe system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
8.3 Specified torques for headlight washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
94 - Lights, bulbs, switches - exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

1 Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
1.1 Assembly overview - headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
1.2 Removing and installing headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
1.3 Adjusting headlight installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
1.4 Renewing headlight bulbs, headlight manufacturer Hella . . . . . . . . . . . . . . . . . . . . . . . . . . 191
1.5 Renewing headlight bulbs, headlight manufacturer Valeo . . . . . . . . . . . . . . . . . . . . . . . . . . 199
1.6 Removing and installing headlight range control motor (headlight manufacturer Hella) . . 207
1.7 Removing and installing headlight range control motor (headlight manufacturer Valeo) . . 208
1.8 Repairing headlight retaining tabs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
1.9 Converting headlights to drive on the left or the right (manufactured by Hella) . . . . . . . . . . 215
1.10 Converting headlights to drive on the left or the right (manufactured by Valeo) . . . . . . . . 218
1.11 Adjusting headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
2 Headlights with gas discharge bulb and cornering light . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
2.1 Assembly overview - headlight with gas discharge bulb and cornering lights . . . . . . . . . . 223
2.2 Removing and installing headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
2.3 Adjusting headlight installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
2.4 Renewing bulbs of headlight with gas discharging bulb and cornering light . . . . . . . . . . . . 225
2.5 Headlight range control motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
2.6 Dynamic cornering light control motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
2.7 Swivel module position sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
2.8 Dipped beam screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
2.9 Power output module for headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
2.10 Removing and installing gas discharge bulb control unit . . . . . . . . . . . . . . . . . . . . . . . . . . 238
2.11 Cornering light and headlight range control unit J745 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
2.12 Vehicle level sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
2.13 Repairing headlight retaining tabs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
2.14 Converting headlights for use when driving on the left or right . . . . . . . . . . . . . . . . . . . . . . 241
2.15 Adjusting headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
3 Fog lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
3.1 Assembly overview - fog lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
3.2 Removing and installing fog light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
3.3 Removing and installing fog light bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
3.4 Checking fog lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
3.5 Adjusting fog lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
4 Front turn signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
Contents iii
4.1 Removing and installing front turn signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248

4.2 Removing and installing turn signal bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
4.3 Checking front turn signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
5 Bulb for mirror turn signal and entry light in exterior mirror . . . . . . . . . . . . . . . . . . . . . . . . 251
5.1 Turn signal repeater bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
5.2 Entry light in exterior mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
6 Tail lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
6.1 Tail light in side panel (saloon) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
6.2 Tail light in rear lid (saloon) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
6.3 Tail light in side panel (Variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
6.4 Tail light in rear lid (Variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
6.5 Tail lights for Canada and USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
7 Number plate light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
7.1 Removing and installing bolted number plate light X (saloon) . . . . . . . . . . . . . . . . . . . . . . 269
7.2 Removing and installing bolted number plate light X (Variant) . . . . . . . . . . . . . . . . . . . . . . 270
7.3 Clipped number plate light X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
7.4 Checking number plate light X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
8 Additional brake lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
8.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
8.2 Removing and installing high-level brake light bulb M25 (saloon) . . . . . . . . . . . . . . . . . . . . 273
8.3 Removing and installing high-level brake light bulb M25 (Variant) . . . . . . . . . . . . . . . . . . . . 273
8.4 Removing and installing high-level brake light bulb M25 (Variant R36) . . . . . . . . . . . . . . . . 274
8.5 Checking high-level brake light bulb M25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
9 Steering column switch up to 10/09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
9.1 Assembly overview - steering column switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
9.2 Removing and installing steering column switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
9.3 Steering column electronics control unit J527 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
9.4 Airbag coil connector and return ring with slip ring F138 . . . . . . . . . . . . . . . . . . . . . . . . . . 281
9.5 Segment sender for steering angle sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
9.6 Steering column combination switch E595 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
10 Steering column switch, vehicles from 11/09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
10.1 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
10.2 Assembly overview - steering column switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
10.3 Removal and installation sequence of components of steering column switch . . . . . . . . . . 286
10.4 Steering column electronics control unit J527 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
10.5 Steering column combination switch E595 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
10.6 Steering column switch carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
11 Ignition/starter switch and lock cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
11.1 Ignition/starter switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
11.2 Lock cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
12 Parking aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
12.2 Assembly overview - parking aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
12.3 Parking aid control unit J446 and park assist steering control unit J791 . . . . . . . . . . . . . . 300
12.4 Front parking aid senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
12.5 Rear parking aid senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
12.6 Parking aid warning buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
12.7 Parking aid button E266 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
12.8 Bonding sender retainer for parking aid and park assist steering in cases of repair . . . . . . 305
13 Park assist steering (PAS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
13.2 Assembly overview of park assist steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
13.3 Park assist steering control unit J791 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
13.4 Front parking aid sender and park assist steering sender . . . . . . . . . . . . . . . . . . . . . . . . 313
iv Contents
13.5 Park assist steering button E581 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316

13.6 Front parking aid warning buzzer H22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
13.7 Rear parking aid warning buzzer H15 (vehicles with park assist steering) . . . . . . . . . . . . 318
14 Entry and start authorisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
14.2 Emergency starting when communication between ID sender and control unit is defective
........................................................................ 320
14.3 Electronic ignition lock D9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
14.4 Convenience system central control unit J393 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
14.5 Entry and start authorisation aerials and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
14.6 Checking entry and start authorisation aerials and sensors . . . . . . . . . . . . . . . . . . . . . . . . 330
14.7 Adapting entry and start authorisation functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
15 Specified torques: lights, bulbs, switches - exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
15.1 Specified torques: headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
15.2 Specified torques: fog lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
15.3 Specified torques: tail light in side panel (saloon) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
15.4 Specified torques: tail light in side panel (Variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
15.5 Specified torques: tail light in rear lid (saloon) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
15.6 Specified torques: tail light in rear lid (Variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
15.7 Specified torques: steering column switch unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
16 Reversing camera system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
16.2 Assembly overview - reversing camera system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
16.3 Removing and installing reversing camera . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
16.4 Reversing camera system control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
16.5 Calibrating reversing camera system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
16.6 Renewing video cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
96 - Lights, bulbs, switches - interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348

1 Interior lights and switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
1.1 Removing and installing interior monitoring deactivation switch E267 and deactivation button
for vehicle inclination sender E360 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
1.2 Footwell lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
2 Lights and switches in engine compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
2.1 Removing and installing bonnet contact switch F266 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
3 Lights and switches in dash panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
3.1 Removing and installing light switch E1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
3.2 Removing and installing headlight range control regulator E102 and switch and instrument
illumination regulator E20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
3.3 Removing and installing electromechanical parking brake button E538 . . . . . . . . . . . . . . 353
3.4 Removing and installing front passenger side airbag deactivated warning lamp K145 . . 355
3.5 Removing and installing glove compartment light W6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
3.6 Removing and installing glove compartment light switch E26 . . . . . . . . . . . . . . . . . . . . . . 358
3.7 Removing and installing hazard warning light switch E3 . . . . . . . . . . . . . . . . . . . . . . . . . . 358
4 Lights and switches in front doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
4.1 Removing and installing driver side switch element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
4.2 Removing and installing driver side interior locking button for central locking system E308
........................................................................ 361
4.3 Removing and installing mirror adjustment switch E43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
4.4 Removing and installing remote release button for fuel filler flap and rear lid E233 . . . . . . 363
4.5 Removing and installing key-operated switch to block release of rear lid remote E232 . . 364
4.6 Removing and installing central locking SAFELOCK function warning lamp K133 . . . . . . 365
4.7 Removing and installing window regulator switch in front passenger door E107 . . . . . . . . 366
4.8 Front left entry light W31 and front right entry light W32 . . . . . . . . . . . . . . . . . . . . . . . . . . 366
4.9 Components - front door locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
Contents v
5 Lights and switches in rear doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369

5.1 Removing and installing rear window regulator switch E52 and E54 . . . . . . . . . . . . . . . . 369
5.2 Rear left entry light W33 and rear right entry light W34 . . . . . . . . . . . . . . . . . . . . . . . . . . 370
5.3 Components - rear door locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
6 Lights and switches in luggage compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
6.1 Luggage compartment light W3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
6.2 Rear lid lock unit F256 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
7 Lights and switches in roof trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
7.1 Front interior light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
7.2 Rear interior and reading lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
7.3 Illuminated vanity mirrors W20 and W14 with contact switches for vanity mirrors F147 and
F148 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
7.4 Garage door opener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
7.5 Automatic anti-dazzle interior mirror Y7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
8 Lights and switches in centre console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
8.1 Removing and installing switches in centre console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
8.2 Removing and installing front ashtray illumination bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
8.3 Removing and installing cigarette lighter U1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
8.4 Removing and installing heated rear seat switches E128 and E129 with regulator . . . . . . 381
8.5 Removing and installing storage compartment illumination bulb L120 . . . . . . . . . . . . . . . . 382
8.6 Removing and installing AC/DC converter with socket, 12 V - 230 V U13 . . . . . . . . . . . . 384
9 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
9.1 Removing and installing treble horn H2 and bass horn H7 . . . . . . . . . . . . . . . . . . . . . . . . 387
9.2 Checking treble horn H2 and bass horn H7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
9.3 Horn plate H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
10 Immobiliser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
10.1 Immobiliser control unit J362 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
10.2 Immobiliser reader unit D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
10.3 Electronic ignition lock D9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
10.4 Electronic steering column lock (ESL) control unit J764 . . . . . . . . . . . . . . . . . . . . . . . . . . 392
10.5 Ignition key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394
10.6 Online system test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
11 Anti-theft alarm (ATA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
11.1 Assembly overview - anti-theft alarm (ATA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398
11.2 Activating and deactivating anti-theft alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399
11.3 Interior monitor deactivation switch E267 and deactivation button for vehicle inclination
sender E360 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400
11.4 Interior monitoring sensor G273 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400
11.5 Interior monitor send and receive module 1 G303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400
11.6 Vehicle inclination sender G384 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
11.7 Central locking and anti-theft alarm system aerial R47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
11.8 Adapting alarm delay on opening driver door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
11.9 Alarm horn H12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
12 Taxi equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
12.1 Onboard supply control unit J519 for special vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
12.2 Special vehicle control unit J608 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
13 Specified torques: lights, bulbs and switches - interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
13.1 Torque settings: alarm horn H12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
13.2 Specified torques: treble horn H2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
13.3 Specified torques: bass horn H7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
97 - Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
1 Vehicle diagnosis, testing and information systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
2 Fuse holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
vi Contents
2.1 Removing and installing fuse holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410

3 Relay carriers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
3.1 Removing and installing relay carrier on left of dash panel . . . . . . . . . . . . . . . . . . . . . . . . 412
3.2 Removing and installing onboard supply control unit J519 . . . . . . . . . . . . . . . . . . . . . . . . 414
4 Electronics boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
4.1 Removing and installing E-box on left side of engine compartment . . . . . . . . . . . . . . . . . . 416
5 Main fuse box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
5.1 Removing and installing main fuse holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
6 Control units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
6.1 Onboard supply control unit J519 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
6.2 Data bus diagnostic interface J533 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427
6.3 Convenience system central control unit J393 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
6.4 Driver door control unit J386 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436
6.5 Front passenger door control unit J387 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
6.6 Coding rear left door control unit J388 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439
6.7 Coding rear right door control unit J389 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
6.8 Trailer detector control unit J345 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442
6.9 Special vehicle control unit J608 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444
6.10 Electronic steering column lock (ESL) control unit J764 . . . . . . . . . . . . . . . . . . . . . . . . . . 447
7 Specified torques: wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448
7.1 Specified torques: fuse holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448
7.2 Specified torques: E-box on left side of engine compartment . . . . . . . . . . . . . . . . . . . . . . 448
7.3 Specified torques: convenience system central control unit J393 . . . . . . . . . . . . . . . . . . . . 448
7.4 Specified torques: special vehicle control unit J608 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448
8 Wiring harness and connector repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449
Contents vii
viii Contents
27 – Starter, current supply, CCS

1 Battery
(VRL006190; Edition 10.2013)
WARNING
Danger of injury! Observe warning notices and safety regula‐

tions ⇒ page 1 !
Caution
To prevent damage to the battery and vehicle, the following

should be observed concerning types of battery ⇒ page 1 .
1.1 Fundamentals for batteries

All the instructions and information for this manual are found in
the workshop manual “Electrical System, General Information”. A
link to this workshop manual is not possible at present for tech‐
nical reasons. Please select the workshop manual “Electrical
System, General Information” manually in ELSA.
1.2 Types of battery

1.3 Warning notices and safety regulations

1.4 Battery terminal connection

1. Battery 1
2 Checking battery
2 Rep. gr.27 - Starter, current supply, CCS

3 Charging battery
3. Charging battery 3
4 Disconnecting and reconnecting bat‐

tery
WARNING

tions ⇒ page 1 !
The following vehicle battery combinations may be installed de‐

pending on the equipment fitted and the type of engine:
Engine Location: engine compartment Location: left in luggage compartment
All petrol engines Battery Additional battery,
(except 3.2 l and 3.6 l ♦ Disconnecting and reconnecting bat‐ »only« with auxiliary coolant heater (op‐
V6 engines) tery ⇒ page 4 tional equipment) or with special vehicle
equipment for example a taxi
♦ Removing and installing battery ♦ Disconnecting and reconnecting addi‐
⇒ page 11 tional battery ⇒ page 6
All diesel engines Battery ♦ Removing and installing additional bat‐
♦ Disconnecting and reconnecting bat‐ tery ⇒ page 18
tery ⇒ page 4
♦ Removing and installing battery
⇒ page 12
3.2 l and 3.6 l V6 pet‐ Battery

rol engines ♦ Disconnecting and reconnecting bat‐
tery ⇒ page 8
♦ Removing and installing battery
⇒ page 20
♦ Pyrotechnic battery isolator
⇒ page 22
4.1 Disconnecting and connecting battery,

vehicles with battery in engine compart‐
ment
Vehicles with an auxiliary coolant heater (optional equipment) or
with special vehicle equipment, for example a taxi, an additional
battery in installed on the left in the luggage compartment
⇒ page 6 .
Note
♦ Disconnecting the battery involves deactivating the anti-theft

coding ⇒ page 399 .
♦ Disconnecting the battery earth cable (open circuit) ensures
safety when working on the electrical system. Disconnecting
the battery positive cable is required only for removal of the
battery. However, observe the notes on disconnecting the bat‐
tery in any case.
4.1.1 Disconnecting battery

– Switch off ignition and all electrical consumers and disengage
ignition key or start button by moving to position 0 (pre-detent).

– Release catch -arrow- and take cover off battery housing.

– First unscrew battery earth terminal clamp -1- from battery
negative terminal.
– Then unscrew battery positive terminal clamp -2- from battery

positive terminal.
4.1.2 Reconnecting battery
Caution
Observe notes for battery terminal clamp bolt ⇒ page 1 .
Special tools and workshop equipment required

♦ Torque wrench - V.A.G 1331-
Note
After the battery has been reconnected and the ignition is switch‐
ed on, the ESP and TCS warning lamp - K155- and electrome‐
chanical power steering warning lamp will light up permanently.
The warning lamps will go out automatically when the vehicle is
driven at 15 to 20 km/h in a straight line. This has the effect of
reactivating the steering angle sender - G85- .
– Fit battery positive wire clamp -2- to battery positive terminal

and tighten securing bolt to specified torque ⇒ page 21 .
4. Disconnecting and reconnecting battery 5

– Fit battery earth wire clamp -1- to battery negative terminal and
tighten securing bolt to specified torque ⇒ page 21 .
– Carry out steps as detailed in the table.
Steps after connecting battery
Procedure Performed
Switch ignition on with ignition
key or start button and then
switch off again.
Read fault memory: ⇒ Guided
fault finding using vehicle diag‐
nosis tester .
Check time on clock and
change as necessary.
Electric window regulators:
– Open and close all windows
to limit stop in each case.
– Finally when window is

closed, pull the switch until
the relay audibly switches.
– Check convenience func‐

tions of window regulator.
The window must close fully
in the convenience mode,
without holding the switch.
Functional check: check all
electrical consumers.
Table can be printed out if necessary.
4.2 Disconnecting and reconnecting bat‐

tery, vehicles with additional battery in
luggage compartment
Vehicles with an auxiliary coolant heater or with special vehicle
equipment, for example a taxi, an additional battery is installed on
the left in the luggage compartment.
Note

tery in any case.
4.2.1 Disconnecting additional battery on left

in luggage compartment

Passat saloon
– Unlock fasteners -arrows- and remove trim panel.
– Release locking lug -arrow- and remove storage compart‐

ment.
Passat Variant
– Release locking devices -1-, remove trim -2- and storage com‐
partment -3-.
Continuation for all vehicles:
– First unscrew battery earth terminal clamp -1- from battery

negative terminal.
– Open terminal cover -arrow- of battery positive terminal.
– Then unscrew battery positive terminal clamp -2- from battery
positive terminal.

4.2.2 Reconnecting additional battery on left

Caution


Note
Positive wire battery clamp must be turned in direction of travel.
– Close terminal cover -arrow-.
4.3 Disconnecting and reconnecting bat‐

tery, vehicles with battery in luggage
compartment
The battery in installed on the left in the luggage compartment on
vehicles with a 3.2 l or 3.6 l V6 petrol engine.

Note

tery in any case.
4.3.1 Disconnecting battery on left in luggage

compartment
Proceed as for disconnecting additional battery ⇒ page 6 .
4.3.2 Reconnecting battery on left in luggage

compartment
Caution

Note
After the battery has been reconnected and the ignition is switch‐
ed on, the ESP and TCS warning lamp - K155- and electrome‐
chanical power steering warning lamp will light up permanently.
The warning lamps will go out automatically when the vehicle is
driven at 15 to 20 km/h in a straight line. This has the effect of
reactivating the steering angle sender - G85- .

Note
Positive wire battery clamp must be turned in direction of travel.

– Close terminal cover -arrow-.

– Carry out steps as detailed in the table.
Steps after connecting battery
Procedure Performed
– Switch ignition on with igni‐
tion key or start button and
then switch off again.
Read fault memory: ⇒ Guided
fault finding using vehicle diag‐
nosis tester .
Check time on clock and
change as necessary.
Electric window regulators:
– Open and close all windows
to limit stop in each case.
– Finally when window is

closed, pull the switch until
the relay audibly switches.
– Check convenience func‐

tions of window regulator.
The window must close fully
in the convenience mode,
without holding the switch.
Functional check: check all
electrical consumers.
Table can be printed out if necessary.

5 Removing and installing battery
WARNING

tions ⇒ page 1 !
5.1 Petrol engine vehicles with battery in‐

stalled in engine compartment
Removing:
– Disconnect battery ⇒ page 4 .
– Pull panel of battery housing out upwards in direction of arrow.
– Unscrew securing bolt -1- and remove securing bracket -2-.
5. Removing and installing battery 11

– Fold up handles -arrows- (if fitted) upwards and remove bat‐

tery.
Installing:
Caution
A loosely fitted battery creates the following dangers:

♦ Shortened service life due to damage from vibration (dan‐
ger of explosion)
♦ The cells in the battery will be damaged if the battery is
not secured correctly.
♦ Damage to battery housing by securing bracket (possibil‐
ity of acid leaking, with high consequential costs)
♦ Poor crash safety.
Installation is carried out in the reverse order. When installing ob‐

serve the following:
– Tighten threaded connections to specified torques
⇒ page 21 .
– After installing, check that battery is seated securely.
– Reconnect battery ⇒ page 4 .
5.2 Diesel engine vehicles with battery in‐

stalled in engine compartment
5.2.1 Vehicles with 1.9 l TDI engine

♦ Spring-type clip pliers - VAS 5024A-

Removing:
– Pull engine cover panel upwards -arrows-.
– Disconnect connector -1- and release spring-type clip -2- us‐

ing spring type clip pliers - VAS 5024A- .
– Pull vacuum hose -arrow- off air filter housing.
– Remove securing bolt of air filter housing -arrow-.

– Release locking lugs -arrows- and take off cover.
– Pull hose -arrow- off air filter housing and remove.

– Pull air filter housing upwards out of brackets and remove.
– Pull panel of battery housing out upwards in direction of

-arrow-.

– Fold up handles -arrows- upwards and remove battery.

Installing:
Caution

ger of explosion)

⇒ page 21 .
5.2.2 Vehicles with 2.0 l TDI engine

♦ Spring-type clip pliers - VAS 5024A-
Removing:

– Separate connector -1-, release spring-type clip -2- with

spring-type clip pliers - VAS 5024A- and pull off vacuum hoses
-3-.


– Pull panel of battery housing out upwards in direction of

-arrow-.


Installing:
Caution

ger of explosion)

⇒ page 21 .
5.3 Vehicles with an additional battery

Vehicles with an auxiliary coolant heater or with special vehicle
equipment, for example a taxi, an additional battery is installed on
the left in the luggage compartment.
5.3.1 Removing and installing battery in en‐

gine compartment
– Remove battery in accordance with motorisation ⇒ page 11 .
5.3.2 Removing and installing additional bat‐

tery on left in luggage compartment
Removing:

– Pull hose for central gas venting -arrow- off battery.

Installing:
Caution

ger of explosion)

⇒ page 21 .

Note
♦ When installing batteries with a hose for central venting, en‐

sure that the hose is not pinched. Only then can the battery
vent freely.
♦ Ensure that the central gas venting hose -1- is inserted into
the rubber grommet -2-.
♦ Ensure that the opening on the upper side of the battery cover
is not blocked on batteries without a hose for central venting.
5.4 Vehicles with battery in luggage com‐

partment
5.4.1 Removing and installing battery on left

Proceed as for removing and installing additional battery
⇒ page 18 .

6 Specified torques: battery
6.1 Specified torques: battery in engine compartment

Threaded connections Specified torques
Battery terminal clamp to battery terminal M6 6 Nm
Additional terminal to battery terminal M6 6 Nm
Securing bolt for retaining strap M8x35 20 Nm
Air filter housing to body 10 Nm
6.2 Specified torques: additional battery/battery in luggage compartment

Battery terminal clamp to battery terminal M6 6 Nm
Securing bolt for retaining strap M8x35 20 Nm
6. Specified torques: battery 21

7 Pyrotechnic battery isolator
WARNING
♦ Battery isolator improves crash safety on vehicles with

battery installed in luggage compartment. In an accident,
the airbag control unit triggers a charge disconnecting the
voltage supply cable to the starter. Battery isolation is per‐
formed pyrotechnically, with a very small explosive
charge. To ensure that you do not trigger the charge in‐
advertently when working on the battery or the battery
isolator, you must first unscrew the negative terminal
clamp ⇒ page 4 .
♦ Observe safety measures when working on the battery
isolator ⇒ page 23 .
♦ Observe notes for disposal of battery isolation units
⇒ page 23 .
Installation of the pyrotechnical battery isolator is equipment-de‐

pendent in conjunction with a starter battery in the luggage com‐
partment. The isolator is integrated into the main fuse box. The
main fuse box is located on the left in the luggage compartment
above the battery.
7.1 Fitting location overview

1 - Connector on pyrotechnical battery isolator
2 - Securing nut (collar nut) for B+ cable and pyrotechnical battery
isolator in main fuse box
3 - B+ wire
4 - Pyrotechnical battery isolator
5 - Securing nut (self-locking) for pyrotechnical battery isolator in
main fuse box
Note
If the battery isolator has triggered, the pyrotechnical battery iso‐

lator must be renewed.

7.2 Safety precautions when working on py‐

rotechnical battery isolator
WARNING
♦ Testing, removing, installing and repair work may only be

performed by qualified personnel.
♦ When work is performed on the battery isolation system,
the battery earth strap must be disconnected.
♦ Before touching the battery isolator, the mechanic must
electrostatically discharge himself. This can be done by
touching a piece of earthed metal such as a water pipe, a
heating pipe or metal girders.
♦ The battery isolation unit should be installed immediately
after it is removed from its transportation packaging.
♦ If the work is interrupted, the battery isolation unit should
again be placed in its transportation packaging.
♦ Battery isolation units must not be left lying unattended.
♦ Battery isolation units which have dropped onto a hard
surface or show signs of damage must not be installed.
♦ The storage and transportation complies with the legisla‐
tion for explosive substances.
7.3 Disposal of pyrotechnical battery isola‐

tion units
WARNING
♦ Non triggered battery isolation units must be disposed of

in their original packaging and by an authorised authority
according to national legislation. All enquires must be di‐
rected to your respective distribution centre or importer.
♦ Triggered battery isolation units can be disposed of
through industrial waste system.
7.4 Removing and installing pyrotechnical

battery isolator
WARNING

♦ Observe notes for disposal of battery isolation units
⇒ page 23 .
Removing:
7. Pyrotechnic battery isolator 23


Passat saloon
– Open locking devices -arrows- and remove flap.
– Release locking lug -arrow- and remove storage compart‐

ment.
Passat Variant
– Release locking devices -1-, remove trim -2- and storage com‐
partment -3-.

– Open fasteners of main fuse box -1- by turning them 90° to left
and open cover downwards.
– Remove flange nut -1- and remove B+ wire -2- from connector
thread.
– Unscrew self-locking nut -4- and remove pyrotechnical battery
isolator -3- from connector thread, taking connected wiring
length into consideration.
– Release connector -1- and pull lock button -3- in direction of

arrow.
– Pull connector -1- off in direction of arrow and remove pyro‐
technical battery isolator -2- from vehicle.
Note
Observe safety measures when working on the pyrotechnical

battery isolator ⇒ page 23 .
Installing:
Note
Ensure, when fitting the connector on the pyrotechnic battery iso‐

lator, that the connector fastener engages audibly.
– Tighten all threaded connections to specified torque

⇒ page 26 .
7. Pyrotechnic battery isolator 25

8 Specified torques: pyrotechnic bat‐

tery isolator
8.1 Specified torques: main fuse box

Securing nut to securing clip M6 9 Nm
Securing nut for B+ cable to main fuse box M8 15 Nm
Lower self-locking securing nut on pyrotech‐ M8 15 Nm
nical battery isolator to main fuse box
Dual bolt for securing main fuse box to main 9 Nm
fuse box bracket

9 Jump start point with suppression fil‐

ter - C24-
Vehicles with the battery in the luggage compartment have an
additional jump start point on the left in the engine compartment.
This consists of the terminal 30 wiring junction - TV2- and the
suppression filter - C24- .
9.1 Fitting location overview

1 - Suppression filter - C24-
2 - Jump start point
3 - Securing nut (collar nut) for term. 30 line to starter - B- and to
threaded connection (30) on E-box
4 - Securing nut (flange nut) for term. 30 line from igniter for bat‐
tery isolator - N253- in the luggage compartment, on the right
5 - Term. 30 line from battery isolation igniter - N253- in the lug‐
gage compartment, on the right
6 - Terminal 30 line to starter - B- and to threaded connection (30)
on E-box
7 - Connector for suppression filter - C24-
8 - Securing bolt
9.2 Removing and installing jump start point

with suppression filter - C24-
Removing:
Note
For purposes of clarity, the air filter housing has been removed.
This is not necessary for repairs.
9. Jump start point with suppression filter C24 27

– Release retaining clip -arrow A- and open cover -1- above the
positive terminal grip.
– Release cover -2- above electrical wiring in direction of
-arrow B-.
– Unscrew securing nuts -5- and -6- from positive wiring.

– Disconnect electrical connector -1- on suppression filter -4-.
– Unscrew bolt -3- and remove the positive terminal grip -2- with
suppression filter from the bracket.
Installing:
Installation is carried out in the reverse sequence.
⇒ page 29 .

10 Specified torques: jump start point

Jump start point with suppression filter - M6 9 Nm
C24- to body
Wiring to term. 30 wiring junction - TV2- M8 15 Nm
10. Specified torques: jump start point 29

11 Starter
11.1 Checking starter - B-

– Connect vehicle diagnosis tester ⇒ page 409 .
Select “Guided fault finding” mode in vehicle diagnosis tester .
– Using “GoTo” button, select “Functions/component” and the
following menu options in succession:
♦ Body
♦ Electrical system
♦ 27 - Starter, current supply
♦ Electrical components
♦ B - Starter
11.2 Removing and installing starter, auto‐

matic gearbox
11.2.1 Vehicles with a 1.6 l FSI engine and au‐

tomatic gearbox
Removing:

– Slide protective cap in direction of -arrow- off solenoid switch.
– Unscrew positive wire -1- and disconnect connector from ter‐

minal 50 -2-.
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Body - front; Noise insulation .
– Remove securing nut -1- from lower securing bolt of starter.

– Remove wiring retainer -2-.
– Remove lower securing bolt of starter -arrow-.
11. Starter 31
– Remove upper securing bolt of starter -arrow-.
– Remove securing nut of earth wire -1- and place end of earth
wire -2- to one side.
– Remove starter from vehicle upwards.
Installing:
Install in the reverse order of removal. When doing this, note the
following:
⇒ page 65 .
11.2.2 Vehicles with 2.0 l FSI turbocharged en‐

gine and automatic gearbox
Removing:

– Remove securing bolts -arrows-.
– Pull off hose -1- after opening clips -2-.

– Disconnect connector -3-.
– Remove securing nut -1- from upper securing bolt of starter.

11. Starter 33

minal 50 -2-.
Note
♦ All hose connections of charge air system are secured with

spring-type clips or push-on connectors. The following points
must be observed for push-on connectors:
♦ Release push-on connection by pulling securing ring -arrow-.
♦ Pull off hose/pipe without tools.
– Loosen screw-type clamp -1- and disconnect connector -2-.

– Remove hose from vehicle.


– Remove starter downwards from vehicle.
Installing:
following:
Note

♦ Push on hose or pipe without tools.
♦ Ensure that locking lugs are securely engaged -arrow-

⇒ page 65 .
11.2.3 Vehicles with a 3.6 l FSI engine and au‐

tomatic gearbox
11. Starter 35
Removing:
– Remove air filter housing complete ⇒ 6-cylinder injection en‐
gine (3.6 l direct injection engine); Rep. gr. 24 ; Assembly
overview - air filter .
– Release and disconnect terminal 50 connector -2-.
– Slide protective cap -1- off solenoid switch in direction of
-arrow-.
– Remove securing nut -2- and place positive wire -1- aside.

– Unclip and open closure -2- and release wiring -1- from clo‐
sure.
– Remove securing nut -3-.
Rep. gr. 50 ; Body - front; Noise insulation; Assembly overview
- noise insulation .
– Unclip and open closure -1- and release wiring -2- from closure
-1-.
– Unscrew securing nut -2- and remove bracket -1- upwards.
11. Starter 37
– Unclip connector -arrow- and separate.
– Remove securing nut -arrow- and place wiring -1- aside.

Installing:
following:
⇒ page 65 .
11.3 Removing and installing starter, dual

clutch gearbox (DSG)
11.3.1 Vehicles with 3.2 l injection engine and dual clutch gearbox (DSG)

Special tools and workshop

equipment required
♦ Torque wrench - V.A.G
1331-
1332-
♦ Spring-type clip pliers -
VAS 5024-
Removing:
– Loosen spring-type clips -1- using spring-type clip pliers - VAS
5024 A- and disconnect connector -2-.
11. Starter 39
– Release locking lug -arrow- and remove cover in direction of

-arrow-.
– Release locking lugs -arrows- and pull air duct forwards in di‐
rection of -arrow- out of retainer.
– Remove securing bolt from air filter housing -arrow-.

– Pull air filter housing upwards out of rubber mounting.
– Take air filter housing out of vehicle.
– Unbolt earth cable -arrow- from gearbox and lay to the side.
Note
To avoid corrosion damage, do not loosen earth cable from earth

point on body.

– Remove securing bolts for air filter bracket -arrows-.

– Remove bracket from vehicle.
– Remove lower securing bolt -arrow- from starter.
– Separate connector -1- and push protective cap -2- down from
solenoid switch in -direction of arrow-.
– Unbolt positive cable -arrow-.
11. Starter 41

Installing:
following:
⇒ page 65 .
11.3.2 Vehicles with 2.0 l TDI engine and dual clutch gearbox (DSG)

equipment required
1331-
1332-
VAS 5024-
Removing:

– Disconnect connector -1-, release spring-type clip -2- with

spring-type clip pliers - VAS 5024A- and pull off vacuum hose
-3-.
11. Starter 43


minal 50 -2-.


Installing:
following:
⇒ page 65 .
11.4 Removing and installing starter, manual

gearbox
11.4.1 Vehicles with 1.6 l injection engine and manual gearbox

equipment required
1331-
1332-
VAS 5024-
Removing:
11. Starter 45
– Loosen spring-type clip -1- using spring-type clip pliers - VAS

5024- and remove securing bolt -2-.
– Release hose -3- and pull it off the air filter housing.
– Pull air filter housing upwards on right-hand side out of rubber

mounting -arrow-.

minal 50 -2-.

– Unscrew earth wire from securing bolt of starter -arrow-.
– Remove securing bolt of starter -arrow-.



Installing:
following:
⇒ page 65 .
11.4.2 Vehicles with 1.6 l FSI engine and man‐

ual gearbox
11. Starter 47
Removing:

minal 50 -2-.




– Remove starter.
Installing:
following:
⇒ page 65 .
11.4.3 Vehicles with 2.0 l FSI engine and manual gearbox
11. Starter 49

equipment required
1331-
1332-
VAS 5024-
Removing:
– Disconnect connector -arrow-.

– Unclip vacuum hose out of retainer -arrow-.
– Loosen spring-type clip -arrow- from hose -1- using spring-

type clip pliers - VAS 5024- .
– Pull hose -1- off air filter housing.
– Remove securing bolt from air filter housing -arrow-.
– Pull air filter housing upwards on right-hand side out of rubber

mounting -arrow-.
11. Starter 51

5024- .
– Pull hose -2- off connection.
– Carefully lift up air filter housing out of vehicle as far as wiring
allows.
– Disconnect connector -arrow- on rear of air filter housing.


minal 50 -2-.




– Remove starter.
Installing:
following:
⇒ page 65 .
11.4.4 Vehicles with 2.0 l FSI turbocharged en‐

gine and manual gearbox
11. Starter 53
Removing:
– Pull off hose -1- after opening clips -2-.



minal 50 -2-.
11. Starter 55



Installing:
following:
⇒ page 65 .
11.4.5 Vehicles with 1.9 l TDI engine and manual gearbox


equipment required
1331-
1332-
VAS 5024-
Removing:
11. Starter 57

– Pull vacuum hose -arrow- off air filter housing.



minal 50 -2-.
11. Starter 59



– Remove starter.
Installing:
following:
⇒ page 65 .
11.4.6 Vehicles with 2.0 l TDI engine and manual gearbox


equipment required
1331-
1332-
VAS 5024-
Removing:
11. Starter 61
– Separate connector -1-, release spring-type clip -2- with

spring-type clip pliers - VAS 5024A- and pull off vacuum hoses
-3-.



minal 50 -2-.

11. Starter 63


– Remove starter.
Installing:
following:
⇒ page 65 .

12 Specified torques: starter

Starter to gearbox M12 80 Nm
Starter to gearbox M10 40 Nm
Earthing wire on starter securing bolt M8 15 Nm
Wiring retainer on starter securing bolt M8 15 Nm
Wiring retainer on starter securing bolt, only ve‐ M8 23 Nm
hicles with a 3.6 l FSI engine and automatic
gearbox
Positive wire to starter solenoid M8 15 Nm
Air filter housing to body M6 10 Nm
Earth wire to automatic gearbox housing M8 15 Nm
12. Specified torques: starter 65

13 Starter, vehicles with 1.8 l TSI engine

and manual gearbox
13.1 Assembly overview
1 - Starter
❑ Removing and installing
⇒ page 67
❑ Checking ⇒ page 30
2 - Battery positive wire con‐
nection to starter
3 - Battery positive wire secur‐
ing nut to starter
❑ M8
❑ 15 Nm
4 - Starter securing bolts
❑ M12
❑ 75 Nm
5 - Protective cap
6 - Wiring retainer securing nut
❑ M8
❑ 23 Nm
7 - Wiring retainer
8 - (Without illustration) air filter
housing securing bolt to body
❑ M6
❑ 10 Nm

13.2 Removing and installing starter, vehicles with 1.8 l TSI engine and manual
gearbox

equipment required
1331-
1332-
VAS 5024-
Removing:
13. Starter, vehicles with 1.8 l TSI engine and manual gearbox 67

– Pull air filter housing upwards out of brackets and remove from
vehicle.


minal 50 -2-.
– Unscrew earth cable from upper starter securing bolt -arrow-.


13. Starter, vehicles with 1.8 l TSI engine and manual gearbox 69

Installing:
following:
– Tighten threaded connections to torques specified in assem‐
bly overview ⇒ page 66 .

14 Alternator
Caution
When batteries are disconnected and reconnected, the proce‐

dure described in the workshop manual must be strictly ob‐
served ⇒ page 4 .
Note
Checking alternator ⇒ Current flow diagrams, Electrical fault find‐

ing and Fitting locations .
14.1 Securing B+ (battery positive) wire to al‐

ternator
Caution
If the battery positive wire is not tightened to the specified tor‐

que, there is a risk of the following:
♦ The battery will not be charged fully.
♦ Vehicle electrics or electronics fail completely (break‐
down).
♦ Danger of fires from sparks
♦ Damage to electronic components and control units due
to excessive voltage
– The specified torque for the battery positive wire securing nut
-arrow- can be found in the “specified torques” table
⇒ page 134 .
14.2 Checking poly V-belt

– Crank engine at vibration damper/belt pulley using a socket.
– Check poly V-belt for:
♦ Sub-surface cracks (cracks, core ruptures, cross sectional
breaks)
♦ Layer separation (top layer, cord strands)
♦ Base break-up
♦ Fraying of cord strands
♦ Flank wear (material wear, frayed flanks, flank brittleness -
glassy flanks-, surface cracks)
14. Alternator 71
♦ Traces of oil and grease
Caution
If faults are found, it is essential for the poly V-belt to be re‐

newed. This will avoid possible breakdowns or operating prob‐
lems.
14.3 Checking alternator - C-

Select “Guided fault finding” mode in vehicle diagnosis tester .
♦ Body
♦ 27 - Starter, current supply
♦ C - Alternator
14.4 Alternator, 1.4 l TSI engine
14.4.1 Assembly overview

1 - Hexagon bolt
❑ 40 Nm
2 - Washer
3 - Idler roller
4 - Washer
5 - Timing case
6 - Hexagon flange nut
❑ M8
❑ Securing nut for B+ wire
on rear of alternator
❑ 15 Nm
7 - Cross-head screw
❑ M5 x 21
❑ 4.5 Nm
8 - Hexagon nut, flat
❑ M8
9 - Washer
❑ M5
10 - Protective cap
11 - Cross-head screws
❑ M4 x 19
❑ 2 Nm
❑ M4 x 13
❑ 2 Nm
13 - Voltage regulator
voltage regulator
⇒ page 131
14 - Alternator
❑ Removing and installing alternator ⇒ page 74
❑ Checking alternator ⇒ page 72
❑ Securing B+ wire to alternator ⇒ page 71
❑ Removing and installing poly V-belt pulley on alternator ⇒ page 127
15 - Poly V-belt
❑ Poly V-belt routing ⇒ Power unit; Rep. gr. 13 ; Dismantling and assembling engine
❑ Checking poly V-belt ⇒ page 71
16 - Hexagon head flange bolts
❑ M8 x 90
❑ 23 Nm
❑ M8 x 50
❑ 25 Nm
18 - Tensioning element
19 - Bracket
❑ For tensioning element and air conditioner compressor
14. Alternator 73
20 - Hexagon head flange bolt

❑ M10 x 50
❑ 20 Nm + 1/4 turn (90°) further
21 - Spacer sleeve
Not illustrated
♦ M5 securing nut on back of alternator for wiring clamp - 3.2 Nm
14.4.2 Removing and installing alternator, 1.4 l

TSI engine
♦ Locking pin - T10060 A-
Removing:
– Pull activated charcoal filter -1- upwards out of fasteners
-arrows-.
– Place activated charcoal filter -1- with connected hoses to one
side.
– Remove poly V-belt ⇒ Power unit; Rep. gr. 13 ; Dismantling
and assembling engine; Removing and installing poly V-belt .

– Remove upper alternator securing bolt -arrow-.

Rep. gr. 50 ; Noise insulation .
– Unscrew wiring retainer -2- and pull off protective cap -1-.
– Disconnect DF connector -1- and unscrew battery positive

wire -2- from alternator.
– Remove securing bolts of air conditioner compressor

-arrows-.
14. Alternator 75
– Release and disconnect connector -1-.

– Unscrew third securing bolt -arrow- and remove air conditioner
compressor from bracket.
Note
♦ The hoses of the air conditioner compressor can remain con‐

nected.
♦ Suspend the air conditioner compressor -3- using a piece of
wire -1- at a suitable position under the vehicle until it is ready
to be reinstalled.
♦ Ensure that the hoses -2- are not stretched or kinked when
doing this.
– Remove lower alternator securing bolt -arrow-.

– Remove alternator from vehicle downwards.
Installing:
following:
Caution
♦ When installing used poly V-belts observe the direction of

rotation marked on removal!
♦ Before installing poly V-belt, ensure that all assemblies
(alternator, air conditioner compressor, vane pump) are
installed correctly.
♦ When fitting belt, ensure that poly V-belt seats correctly in
pulleys!
– Drive threaded sleeves -A- about 4 mm in direction of

-arrow- out of alternator housing.

– Tighten cable retainer -arrow- to rear of alternator in 9 o'clock

position.
– Start engine and check belt is running correctly.
14.5 Alternator, 1.8 l TSI engine
14.5.1 Alternator, 1.8 l TSI engine

❑ M8x110
❑ 20 Nm
❑ M4x19
❑ 2 Nm
3 - Washer
❑ M5
❑ M5x21
❑ 4.5 Nm
5 - Hexagon nut
❑ M8
❑ 15 Nm
❑ M8
7 - Protective cap for alternator
❑ M4x13
❑ 2 Nm
voltage regulator
⇒ page 131
10 - Alternator
alternator ⇒ page 78
❑ Checking alternator
⇒ page 72
❑ Removing and installing poly V-belt pulley ⇒ page 127
11 - Poly V-belt
❑ Removing and installing ⇒ Power unit; Rep. gr. 13 ; Dismantling and assembling engine
14. Alternator 77
❑ Poly V-belt routing ⇒ Power unit; Rep. gr. 13 ; Dismantling and assembling engine

TSI engine
Caution

served ⇒ page 4 .

Removing:
Caution
Before removing, mark the top side and direction of rotation of

the poly V-belt. When installing, ensure correct fitting position
and direction of rotation. If the belt is installed in the wrong
position or against direction of rotation, the belt will be de‐
stroyed!

and assembling engine .


– Unscrew oil pressure switch -1- (24 mm).
– Remove securing bolts -arrows- of alternator.
– Swing alternator slightly to the left to gain access to connec‐
tions on generator side.
– Release and disconnect connector of DF cable -1-.
– Lever off protective cap -1-.
– Remove securing nut -2- and remove the B+ cable -1-, located
beneath, from the connector thread of the alternator.
14. Alternator 79
– Remove both securing bolts -arrows- and put pipework and

hose -1- up to make room for removing generator.
Note
Pipework and hose can remain connected.
– Lift alternator out of vehicle.

Installing:
following:
Caution

♦ Before installing poly V-belt, ensure that all ancillaries (al‐
ternator, air conditioner compressor) are secure.
pulleys!

14.6 Alternator, 1.6 l injection engine


❑ M8x108
❑ 23 Nm
❑ M8x50
❑ 23 Nm
3 - Bracket
❑ M8
❑ M8x45
❑ 52 Nm
6 - Protective cap
❑ M8
❑ M5x21
❑ 4.5 Nm
❑ M8
10 - Washer
❑ M5
❑ M4x19
❑ 2 Nm
❑ M4x13
❑ 2 Nm
❑ Removing and installing voltage regulator ⇒ page 131
14 - Alternator
15 - Poly V-belt
16 - Ancillary bracket
❑ For alternator and air conditioner compressor
❑ Tightening sequence ⇒ page 134
17 - Poly V-belt tensioning element
❑ M8x90
❑ 23 Nm
14. Alternator 81

injection engine
Caution

served ⇒ page 4 .

Removing:

– Disconnect DF wire connector -1- and pull off protective cap

-2-.
– Unscrew B+ (battery positive) wire -arrow- from alternator.
Caution

stroyed!
– Mark direction of rotation of poly V-belt.
– Release tension of poly V-belt by swivelling tensioning ele‐

ment in -direction of arrow-.
– Lock tensioning element using locking pin - T10060 A- .

– Remove poly V-belt.
14. Alternator 83
– Unclip coolant hose from hose bracket -1- and unscrew se‐
curing nut -2-.

– Remove holder together with clamping element from vehicle.
– Remove securing bolts of alternator -arrows-.
– Unscrew wiring retainer -arrow- from alternator.

– Remove alternator.
Installing:
following:
Caution

pulleys!



position.
⇒ page 134 .
Caution

– Switch off engine.
14.6.3 Poly V-belt routing, 1.6 l injection engine

Vehicles without air conditioner:
1- Tensioning roller
2- Poly V-belt pulley - alternator
3- Poly V-belt
4- Poly V-belt pulley - crankshaft
Vehicles with an air conditioner:

3- Poly V-belt pulley - air conditioner compressor
4- Poly V-belt
14. Alternator 85
14.7 Alternator, 1.6 l FSI engine
1 - Hexagon bolt
❑ 40 Nm
❑ M8x90
2 - Washer
3 - Idler roller
4 - Washer
5 - Timing case
❑ M8
❑ M5x21
❑ 4.5 Nm
❑ M8
9 - Washer
❑ M5
10 - Protective cap
❑ M4x19
❑ 2 Nm
❑ M4x13
❑ 2 Nm
voltage regulator
⇒ page 131
14 - Alternator
15 - Poly V-belt
❑ Checking poly V-belt ⇒ page 71
❑ M8x90
❑ 23 Nm
❑ M8x50
❑ 25 Nm
18 - Tensioning element
19 - Bracket
❑ For tensioning element and air conditioner compressor


❑ M10x50
❑ 20 Nm + 1/4 turn (90°) further
21 - Spacer sleeve
14.7.2 Removing and installing alternator, 1.6 l FSI engine

equipment required
1331-
VAS 5024 A-
Removing:
14. Alternator 87
– Loosen spring-type clip -arrow- with spring type clip pliers -

VAS 5024 A- and pull hose off.
– Pull off hose -1- and separate connector -2-.
– Loosen hose clip -1- and release locking lugs -arrows-. Re‐
move hose.

– Remove securing bolts -arrows- and remove heat shield from

vehicle.
Rep. gr. 50 ; Noise insulation .
Caution

stroyed!
– Release tension on poly V-belt by levering back tensioning el‐

ement in direction of arrow using a 16 mm open-jaw spanner
and lock tensioning element with locking pin - T10060 A- .
– Remove idler roller securing bolts -arrows- and remove idler

roller from bracket.
– Remove securing bolts for alternator -arrows-.

– Remove alternator from bracket and turn it to gain access to
the push-fit and screwed connections.
14. Alternator 89

-2-.

– Remove alternator from vehicle downwards.
Installing:
following:
Caution

ternator, air conditioner compressor, vane pump) are se‐
cure.
pulleys!
– Drive threaded sleeve -A- about 4 mm in direction of arrow out

of alternator housing.


position.
⇒ page 134 .
14.7.3 Poly V-belt routing, 1.6 l FSI engine

1- Poly V-belt pulley – coolant pump
3- Poly V-belt pulley – alternator
4- Poly V-belt
5- Poly V-belt pulley – crankshaft

2- Idler roller
5- Poly V-belt pulley – air conditioner compressor
6- Poly V-belt
14.8 Alternator, 2.0 l FSI engine
14. Alternator 91

❑ M8x90
❑ 23 Nm
❑ M8x50
❑ 23 Nm
3 - Transportation bracket
4 - Poly V-belt tensioning ele‐
ment
❑ For alternator and air
conditioner compressor
❑ Tightening sequence
⇒ page 134
❑ M10x45
❑ 52 Nm
7 - Protective cap
❑ M8
❑ M5x21
❑ 4.5 Nm
❑ M8
11 - Washer
❑ M5
❑ M4x19
❑ 2 Nm
❑ M4x13
❑ 2 Nm
15 - Alternator
16 - Poly V-belt

14.8.2 Removing and installing alternator, 2.0

l FSI engine
Caution

served ⇒ page 4 .

equipment required
1331-
VAS 5024 A-
Removing:
14. Alternator 93
Caution

stroyed!

ment in direction of -arrow- using a 16 mm open-jaw spanner.
– Lock tensioning element -2- using locking pin - T10060 A-

-1-.
– Unclip coolant hose -arrows-.

– Remove securing bolts from tensioning element -arrows-.

– Remove tensioning element together with lifting eye -1- out of
vehicle.

– Remove alternator from bracket and turn it to gain access to
the push-fit and screwed connections.

-2-.
14. Alternator 95

– Remove alternator from vehicle.
Installing:
following:


position.
⇒ page 134 .
Caution

pulleys!
Caution


14.8.3 Poly V-belt routing, 2.0 l FSI engine

3- Poly V-belt

4- Poly V-belt
14.9 Alternator, 2.0 l FSI turbocharged en‐

gine
14. Alternator 97

❑ M8x45
❑ 23 Nm
❑ M8x90
❑ 23 Nm
⇒ page 135
❑ M10x45
❑ 45 Nm
5 - Protective cap
❑ M8
❑ M5x21
❑ 4.5 Nm
❑ M8
9 - Washer
❑ M5
❑ M4x19
❑ 2 Nm
❑ M4x13
❑ 2 Nm
13 - Alternator
14 - Poly V-belt
15 - Poly V-belt tensioning element
14.9.2 Removing and installing alternator, 2.0

l FSI turbocharged engine

Removing:
– Open retaining clips -1- and pull hose -2- off air filter housing.
14. Alternator 99
Caution

stroyed!


– Loosen the threaded connections of the coolant pipe

-arrows-.
Note
The coolant pipe can remain installed. It will have to be loosened

in order to be able to remove the alternator.


-2-.

– Remove alternator from vehicle.
Installing:
following:
Caution

pulleys!
14. Alternator 101



position.
⇒ page 134 .
Caution

14.9.3 Poly V-belt routing, 2.0 l FSI turbo‐

charged engine
3- Poly V-belt

4- Poly V-belt

14.10 Alternator, 3.6 l FSI engine and 3.2 l in‐

jection engine
1 - Multi-point socket head bolt

❑ For tensioning element
⇒ Item 2 (page 103) .
❑ M10x85
❑ 50 Nm
ment
❑ For alternator
⇒ Item 17 (page 104) .
❑ M8x90
❑ 23 Nm
⇒ page 136
5 - Multi-point socket head
bolts
❑ For ancillary bracket
⇒ Item 4 (page 103)
❑ M8x50
❑ 23 Nm
6 - Multi-point socket head fit‐
ted bolts
❑ For ancillary bracket
⇒ Item 4 (page 103)
❑ M8x28
❑ 23 Nm
7 - Hexagon socket head col‐
lard bolts
❑ For bracket ⇒ Item 8 (page 103) .
❑ M6x16
❑ 8 Nm
8 - Bracket
❑ For circulation pump - V55- .
9 - Protective cap
❑ M8
❑ M5x21
❑ 4.5 Nm
❑ M8
14. Alternator 103

13 - Washer
❑ M5
❑ M4x19
❑ 2 Nm
❑ M4x13
❑ 2 Nm
17 - Alternator
18 - Poly V-belt
19 - O-ring
❑ For idler roller ⇒ Item 22 (page 104)
20 - Dust cap
❑ M10x36
❑ 40 Nm
22 - Idler roller
❑ With deep groove ball bearing.
23 - Dust cap

FSI engine and 3.2 l injection engine

Removing:
Rep. gr. 50 ; Body - front; Noise insulation; Assembly overview
- noise insulation .
– Remove front section of right wheel housing liner ⇒ General
body repairs, exterior; Rep. gr. 66 ; Wheel housing liner; Re‐
moving and installing front wheel housing liner .
Caution

stroyed!

– Lock tensioning element -2- using locking pin - T10060 A-

-1-.
Remove air conditioner compressor and secure compressor to
body using suitable material (e.g. welding wire) ⇒ Heating and
air conditioning system; Rep. gr. 87 .
14. Alternator 105

– Remove securing nut -arrow- of wiring retainer.
– Release and disconnect terminal 61 connector -2-.

– Remove protective cap -1-.
– Unclip and open closure -3- and release wiring from closure.
– Remove securing nut -1- of B+ wire -2- from alternator and

move B+ wire aside.

– Unscrew securing bolt -1- of tensioning roller -2- and remove

tensioning roller.
– Unscrew securing bolts of alternator -arrows-.

Installing:
following:
Caution

pulleys!


position.
⇒ page 136 .
Caution

14. Alternator 107

14.10.3 Poly V-belt routing, 3.6 l FSI engine and

3.2 l injection engine
3- Idler roller
4- Poly V-belt pulley – air conditioner compressor
5- Idler roller
8- Poly V-belt
14.11 Alternator, 1.6 l TDI engine
1 - Hexagon bolt with washer

and threaded element
❑ M4 x 20, M4 x 15
❑ 2 Nm
❑ M4 x 20
❑ 2 Nm
4 - Protective cap for carbon
brushes
voltage regulator
⇒ page 131
6 - Alternator
❑ Checking alternator
⇒ page 72
❑ Securing B+ wire to al‐
ternator ⇒ page 71
poly V-belt pulley on al‐
ternator ⇒ page 127
7 - Poly V-belt
❑ Poly V-belt routing ⇒
Power unit; Rep. gr. 13 ;
Dismantling and assem‐
bling engine
❑ Checking poly V-belt
⇒ page 71
❑ M8 x 90

❑ 20 Nm
Not illustrated
♦ M5 securing nut on back of alternator for wiring clamp - 3.2 Nm
♦ M8 securing bolts of air conditioner compressor on ancillary
bracket - 23 Nm

TDI engine
Caution

served ⇒ page 4 .

Removing:
– Place lock carrier in service position ⇒ General body repairs,
exterior; Rep. gr. 50 ; Moving to service position .
Caution

stroyed!

14. Alternator 109


-arrows-.
Note

nected.
♦ Until reinstallation, suspend air conditioner compressor at a
suitable position using a piece of wire.
♦ When doing this, ensure that hoses are not stretched or
kinked.
– Release and disconnect DF wire connector -1-.

– Remove securing nut -1- and remove the battery positive wire,
located beneath, from the connector thread of the alternator.
– Unscrew securing nut -3- and remove wiring retainer -2- from
the alternator.

– Unscrew both securing bolts -1- and securing nut -2- of fuel
filter -3- and place filter to one side. The fuel hoses can then
remain connected.
– Remove both securing bolts of alternator -arrows-.

Installing:
following:
Caution

ternator, air conditioning compressor) are secure.
pulleys!

14. Alternator 111


position.
Caution

served ⇒ page 4 .

14.12 Alternator, 1.9 l and 2.0 l TDI engine (2

valves per cylinder)

❑ M8x45
❑ 25 Nm
ment
❑ M8x90
❑ 25 Nm
⇒ page 137
❑ M10x65
❑ 40 Nm
❑ M10x45
❑ 40 Nm
❑ M4x20, M4x15
❑ 2 Nm
❑ M4x20
❑ 2 Nm

10 - Protective cap for carbon brushes

12 - Alternator
13 - Poly V-belt
14.12.2 Removing and installing alternator, 1.9 l and 2.0 l TDI engine (2 valves per
cylinder)

equipment required
1331-
VAS 5024 A-
Removing:
14. Alternator 113

Note

♦ Release push-on connection by pulling securing ring -arrow-.
♦ Pull off hose/pipe without tools.

5024 A- and separate connector -2-.
– Remove charge air hose from vehicle.

-2-.


– Pull fuel filter out of bracket and place to one side. When doing
this, the fuel hoses can remain connected.
Caution

stroyed!

– Unbolt cable retainer from alternator -arrow-.

Installing:
following:
Caution

pulleys!
14. Alternator 115



position.
Note

♦ Push on hose or pipe without tools.
♦ Ensure that locking lugs are securely engaged -arrow-

⇒ page 134 .
Caution


14.12.3 Poly V-belt routing, 1.9 l and 2.0 l TDI

engine (2 valves per cylinder)
3- Poly V-belt

4- Poly V-belt
14.13 Alternator, 2.0 l TDI engine (4 valves per

cylinder)
14. Alternator 117


❑ M8x45
❑ 20 Nm
ment
❑ M8x90
❑ 20 Nm
⇒ page 137
❑ M10x65
❑ 40 Nm
❑ M10x45
❑ 40 Nm
❑ M4x20
❑ 2 Nm
8 - Protective cap
voltage regulator
⇒ page 131
10 - Alternator
11 - Poly V-belt

TDI engine (4 valves per cylinder)
Removing:


Vehicles with engine code BKP, BMA BVE or BWV
– Pull off vacuum hoses -arrows-.

– Remove vacuum reservoir with bracket together.
Vehicles with engine code BMR or BUZ
– Disconnect connector -1-, pull off vacuum hose -2- and unclip
line from retainer -3-.
14. Alternator 119

– Unclip valve -4- and move aside.
– Unscrew securing bolts -arrows- and remove bracket from in‐

take manifold.

-2-.

– Remove fuel filter and place it aside ⇒ 4-cyl. 2.0 l, 4 valve
diesel engine; Rep. gr. 20 ; Parts of fuel system .
Note
The fuel hoses remain connected.
Caution

stroyed!

– Release poly V-belt tension by levering back tensioning ele‐

ment in direction of arrow using a 16 mm open-jaw spanner


Installing:
following:
Caution

pulleys!
14. Alternator 121



position.
⇒ page 134 .
Caution

14.13.3 Poly V-belt routing, 2.0 l TDI engine (4

valves per cylinder)
3- Poly V-belt

4- Poly V-belt

14.14 Alternator, 2.0 l TDI common rail injec‐

tion engine
♦ Assembly overview, alternator, 2.0 l TDI common rail injection
engine ⇒ page 123
♦ Removing and installing alternator, 2.0 l TDI common rail in‐
jection engine ⇒ page 123
14.14.1 Assembly overview - alternator, 2.0 l TDI common rail injection engine

❑ M4x20, M4x15
❑ 2 Nm
❑ M4x20
❑ 2 Nm
4 - Protective cap for carbon
brushes
voltage regulator
⇒ page 131
6 - Alternator
7 - Poly V-belt
⇒ Power unit; Rep. gr.
13 ; Dismantling and as‐
sembling engine
❑ Poly V-belt routing ⇒
Power unit; Rep. gr. 13 ;
Dismantling and assem‐
bling engine
❑ M8x90
❑ 25 Nm
Not illustrated
♦ M5 securing nut of wiring retainer on rear side of alternator –
3.2 Nm
♦ Poly V-belt pulley with freewheel – 80 Nm
♦ Removing and installing ancillary bracket ⇒ Power unit; Rep.
gr. 13 ; Dismantling and assembling engine

TDI common rail injection engine
14. Alternator 123

Removing:
exterior; Rep. gr. 50 ; Moving to service position .
Caution

stroyed!



-arrows-.
Note

nected.
♦ Until reinstallation, suspend air conditioner compressor at a
suitable position using a piece of wire.
♦ When doing this, ensure that hoses are not stretched or
kinked.
– Release and disconnect DF wire connector -1-.

– Remove securing nut -1- and remove the battery positive wire,
located beneath, from the connector thread of the alternator.
– Unscrew securing nut -3- and remove wiring retainer -2- from
the alternator.
– Unscrew both securing bolts -1- and securing nut -2- of fuel
filter -3- and place filter to one side. The fuel hoses can then
remain connected.
14. Alternator 125

– Remove both securing bolts of alternator -arrows-.

Installing:
following:
Caution

pulleys!


position.

Caution


14.15 Removing and installing poly V-belt pul‐

ley on alternator
14.15.1 Removing and installing poly V-belt pul‐

ley without freewheel
♦ Socket - VAS 3310-
Removing:
– Remove alternator ⇒ page 71 .
– Clamp alternator on bracket points in bench vice.
– Use socket - VAS 3310- to unscrew poly V-belt pulley securing
nut from alternator shaft.
Installing:
⇒ page 134 .
14.15.2 Removing and installing poly V-belt pul‐

ley with freewheel, manufacturer: Bosch
14. Alternator 127

♦ Multipoint adapter - VAS 3400-
Removing:
– Remove protective cap from poly V-belt pulley with freewheel.
– Insert multi-point adapter - VAS 3400- with ring spanner 17
mm in poly V-belt pulley with freewheel of alternator.
– Insert a M10 multi-point bit -1- into alternator shaft.
– Loosen threaded connection by turning clockwise. Counter‐
hold with ring spanner when doing this.
– Hold poly V-belt pulley with freewheel by hand. Turn drive
shaft of alternator until poly V-belt pulley with freewheel can
be removed.
Installing:
following:
– First screw poly V-belt pulley with freewheel on drive shaft of
alternator by hand as far as limit stop.
The torque wrench - V.A.G 1332- must be modified for assembly
of poly V-belt with freewheel as follows:

– Release socket drive -1- and pull off grip -2-.

– Turn grip -2- of torque wrench through 180 degrees and rein‐
sert socket drive.
– Set turning direction of torque wrench to anti-clockwise on
socket drive.
– Insert a M10 multi-point bit -1- into alternator shaft.

– Counterhold using multi-point adapter - VAS 3400- and ring
spanner 17 mm.
– Tighten poly V-belt with freewheel by turning drive shaft of al‐
ternator clockwise using torque wrench - V.A.G 1332- .
⇒ page 134 .
14.15.3 Removing and installing poly V-belt pulley with freewheel, manufacturer:
Valeo
14. Alternator 129


equipment required
♦ Multipoint adapter - VAS
3400-
1332-
♦ TORX driver bit - V.A.G
1603/1-
Removing:
– Remove protective cap from poly V-belt pulley with freewheel.
– Insert multi-point adapter - VAS 3400- with ring spanner 17
mm in poly V-belt pulley with freewheel of alternator.

– Insert TORX driver bit - V.A.G 1603/1- in alternator shaft.

– Loosen threaded connection by turning clockwise. Counter‐
hold with ring spanner when doing this.
– Hold poly V-belt pulley with freewheel by hand. Turn drive
shaft of alternator until poly V-belt pulley with freewheel can
be removed.
Installing:
following:
– First screw poly V-belt pulley with freewheel on drive shaft of
alternator by hand as far as limit stop.
The torque wrench - V.A.G 1332- must be modified for assembly
of poly V-belt with freewheel as follows:
– Release socket drive -1- and pull off grip -2-.

– Turn grip -2- of torque wrench through 180 degrees and rein‐
sert socket drive.
– Set turning direction of torque wrench to anti-clockwise on
socket drive.
– Insert TORX driver bit - V.A.G 1603/1- in alternator shaft.

– Counterhold using multi-point adapter - VAS 3400- and ring
spanner 17 mm.
– Tighten poly V-belt with freewheel by turning drive shaft of al‐
ternator clockwise using torque wrench - V.A.G 1332- .
⇒ page 134 .
14.16 Voltage regulator for alternator
14.16.1 Removing and installing voltage regula‐

tor, manufacturer: Bosch
14. Alternator 131

♦ Torque screwdriver - V.A.G 1624-
Removing:
– Remove securing bolt and nuts -arrows- and take protective
cap off alternator.
– Remove securing bolts for voltage regulator -arrows-.

– Remove voltage regulator from alternator.
Installing:
Installation is carried out in reverse order of removal.
⇒ page 134 .
14.16.2 Removing and installing voltage regula‐

tor, manufacturer: Valeo
♦ Torque wrench - V.A.G 1783/-

Removing:
– Remove spring clips -arrows- and take protective cap off al‐
ternator.
– Remove securing bolts for voltage regulator -arrows-.

– Remove voltage regulator from alternator.
Installing:
following:
– Release locking lugs -arrows- and pull protective cap off volt‐
age regulator.
– Push carbon brushes in housing of voltage regulator and place
voltage regulator in alternator.
⇒ page 134 .
– Push protective cap in guides -arrows- until it can be heard to

engage.
14. Alternator 133

15 Specified torques: alternator
15.1 General specified torques for all vehicles

B+ wire to alternator M8 15 Nm
Cable holder to alternator M5 3.2 Nm
Voltage regulator to alternator (Bosch, Valeo) M4 2 Nm
Protective cap to alternator (Bosch) M5 4.5 Nm
Poly V-belt pulley with freewheel to alternator M10 80 Nm
Poly V-belt pulley without freewheel to alternator M10 65 Nm
15.2 1.6 l injection engine and 2.0 l FSI en‐

gine
Caution
In order to avoid damage to cylinder block and ancillaries

bracket, adhere strictly to the tightening sequence for the an‐
cillaries bracket.
15.2.1 Specified torques

Alternator on ancillary M8 23 Nm
bracket
Tensioning element on an‐ M8x50 23 Nm
cillary bracket
Ancillary bracket on cylin‐ M10x45 52 Nm
der block

15.2.2 Tightening sequence of ancillary brack‐

et, vehicles without air conditioning sys‐
tem
Tightening sequence for ancillary bracket on cylinder block
Procedure:
– Place ancillary bracket on cylinder block.
Note
Before tightening to specified torque, screw in all bolts by hand.
– Tighten securing bolts of ancillary bracket in following se‐

quence:
A - M10x45 hexagon head flange bolt, 52 Nm, fitting hole
B - M10x45 hexagon head flange bolt, 52 Nm
C - M10x45 hexagon head flange bolt, 52 Nm
D - M10x45 hexagon head flange bolt, 52 Nm

et, vehicles with air conditioning system
Procedure:
Note

quence:
A - M10x45 hexagon head flange bolt, 52 Nm, fitting hole
E - M10x45 hexagon head flange bolt, 52 Nm
F - M10x45 hexagon head flange bolt, 52 Nm
15.3 2.0 l FSI turbocharged engine
Caution

cillaries bracket.
15. Specified torques: alternator 135


Alternator on ancillary M8x90 23 Nm
bracket
cillary bracket
Ancillary bracket on cylin‐ M10x45 40 Nm
der block
Air conditioner compressor M8x100 23 Nm
on ancillary bracket

Procedure:
Note
– Tighten securing bolts of ancillaries bracket in following se‐

quence:
A - Socket head bolt, M10x45, 40 Nm, bore
B - Socket head bolt, M10x45, 40 Nm
C - Socket head bolt, M10x45, 40 Nm
D - Socket head bolt, M10x45, 40 Nm
E - Socket head bolt, M10x45, 40 Nm
F - Socket head bolt, M10x45, 40 Nm
15.4 3.6 l FSI engine and 3.2 l injection en‐

gine
Caution

cillaries bracket.

Alternator on ancillary M8x90 23 Nm
bracket
cillary bracket
Air conditioner compressor M8x90 23 Nm
on ancillary bracket
Ancillary bracket on cylin‐ M8 23 Nm
der block


Procedure:
Note

quence:
A - Hexagon socket head bolt, M8x28, 23 Nm, bore
B - Hexagon socket head bolt, M8x28, 23 Nm, bore
C - Multi-point socket head bolt, M8x50, 23 Nm
D - Multi-point socket head bolt, M8x50, 23 Nm
E - Multi-point socket head bolt, M8x50, 23 Nm
15.5 1.9 l and 2.0 l TDI engine
Caution

cillaries bracket.

Alternator on ancillary bracket M8x90 20 Nm
Tensioning element on ancillary bracket M8 20 Nm
Ancillary bracket on cylinder block M10 40 Nm
Retainer (transportation bracket) on intake M8 20 Nm
manifold
15. Specified torques: alternator 137


et
Procedure:
Note
♦ Take note of dowel sleeve between ancillary bracket and cyl‐

inder block.
♦ Before tightening to specified torque, screw in all bolts by
hand.

quence:
A - M10x65 hexagon head flange bolt, 40 Nm
E - M10x65 hexagon head flange bolt, 40 Nm
F - Hexagon head collared bolt, M10x65, with sleeve 40 Nm

16 Cruise control system (CCS)

General description:
The functions of the cruise control system are controlled by the
engine control unit.
The cruise control system switch - E45- is part of the steering
column combination switch - E595- and cannot be renewed indi‐
vidually.
– Removing and installing steering column combination switch
- E595- (with cruise control system switch - E45- )
⇒ page 282 .
– The cruise control system can be activated/deactivated
⇒ page 139 .
Fault detection and fault display:
Faults on the CCS are output via the engine control unit.
For fault finding, use the systems described in chapter “Vehicle
diagnosis, testing and information system” in “Guided Fault Find‐
ing” mode ⇒ page 409 .
16.1 Activating and deactivating cruise con‐

trol system (CCS)
16. Cruise control system (CCS) 139

17 Adaptive cruise control (ACC)
Note
Additional information:
⇒ Operating manual
⇒ Self-study programme No. 339 ; The Passat 2006
⇒ Self-study programme No. 340 ; The Passat 2006 - Electrical
System
⇒ Self-study programme No. 356 ; The Passat Variant 2006
⇒ Self-study programme No. 276 ; The Phaeton - Adaptive cruise
control (ACC)
⇒ Current flow diagrams, Electrical fault finding and Fitting loca‐
tions
Adaptive cruise control (ACC) is an assistance system for the
driver which expands the functions of the cruise control system
(CCS). An ACC vehicle is kept at a convenient adjustable dis‐
tance from a slower vehicle in front by reducing the engine torque
and operating the brakes if necessary. The status of the ACC
system is influenced by the keys of the adaptive cruise control -
E357- on the steering wheel, the accelerator and brake pedal, the
selector lever and the internal vehicle interventions of the brake
system.
The adaptive cruise control unit - J428- is equipped with self-di‐
agnosis, which is designed to simplify fault finding.
Initialising before first use or when renewing adaptive cruise con‐
trol unit - J428- ⇒ page 142
17.1 Assembly overview

1 - Adaptive cruise control but‐

ton - E357-
The adaptive cruise control
button - E357- is a component
of the CCS positive switch on
the steering column.
Removing and installing GRA

positive switch on steering col‐
umn ⇒ page 141
2 - Adaptive cruise control unit

- J428-
The adaptive cruise control
unit - J428- cannot be disman‐
tled and comprises the follow‐
ing components:
♦ Adaptive cruise control unit
- J428-
♦ Adaptive cruise control
sensor - G550-
♦ Sensor heater for adaptive
cruise control system - Z47-
Removing and installing adap‐
tive cruise control unit - J428-
⇒ page 141
17.2 Removing and installing adaptive cruise

control button - E357-
The adaptive cruise control button - E357- is a component of the
CCS positive switch on the steering column.
Removing and installing GRA positive switch on steering column
⇒ page 276
17.3 Removing and installing adaptive cruise

control unit - J428-
The adaptive cruise control unit - J428- is installed behind the VW
badge in the radiator grille in the front of the vehicle.
The adaptive cruise control unit - J428- cannot be dismantled and
comprises the following components:
♦ Adaptive cruise control sensor - G550-
♦ Sensor heater for adaptive cruise control system - Z47-
Removing:
17. Adaptive cruise control (ACC) 141

– Remove radiator grille ⇒ General body repairs, exterior; Rep.

gr. 66 ; Radiator grille; Mouldings and trims; Assembly over‐
view - radiator grille .
– Unclip adaptive cruise control unit - J428- -1- from the three
fasteners -2-.
– Swing adaptive cruise control unit - J428- -1- forwards, taking
connected wiring length into consideration.
– Release and disconnect the connector -2- and remove auto‐

matic distance regulation unit - J428- from vehicle.
Installing:
following:
The adaptive cruise control sensor - G550- in the adaptive cruise
control unit - J428- must be adjusted after:
♦ Each removal and installation or renewal of the adaptive cruise
control sensor - G550-
♦ Each removal and installation or replacement of the assembly
carrier
♦ When excessive force has been exerted on these compo‐
nents, after a collision or similar.
Adjusting distance regulation sensor - G550- ⇒ page 142 .
– Initialising before first use or when renewing adaptive cruise
control unit - J428- ⇒ page 142
17.4 Calibrating adaptive cruise control sen‐

sor - G550-
The adaptive cruise control sensor - G550- in the adaptive cruise
control unit - J428- must be calibrated after:
♦ Each removal and installation or renewal of the adaptive cruise
control sensor - G550-
♦ Each removal and installation or replacement of the assembly
carrier
♦ When excessive force has been exerted on these compo‐
nents, after a collision or similar.
Calibrating adaptive cruise control sensor - G550- ⇒ Running
gear, axles, steering; Rep. gr. 44 ; Adaptive cruise control (ACC)
17.5 Initialising adaptive cruise control
Note
Initialising is only required before first use or when renewing the

adaptive cruise control unit - J428- .

♦ Vehicle diagnosis tester
♦ Diagnostic cable - VAS 5051/6A-

Select “Guided fault finding” in vehicle diagnosis tester .
♦ Running gear
♦ Cruise control
♦ Functions
♦ Adaption after replacing control unit
17. Adaptive cruise control (ACC) 143

90 – Gauges, instruments
1 Dash panel insert
Note
♦ Dash panel insert functions and components can be checked

by way of dash panel insert final control diagnosis
⇒ page 145 .
♦ Additional information:

System
⇒ Maintenance ; Booklet 21.1
Integrated in the dash panel insert are the following components:
♦ Control unit with display in dash panel insert - J285-
♦ Engine oil temperature gauge
♦ Rev. counter
♦ Coolant temperature gauge
♦ Multifunction display
♦ Fuel gauge
♦ Speedometer
♦ Warning lamps ⇒ page 147
All warning lamps feature LEDs. No provision has been made for
repair of the dash panel insert. If necessary, the dash panel insert
is renewed as a unit ⇒ page 144 .
Note
The immobiliser control unit - J362- is integrated in the conven‐

ience system central control unit - J393- .

The dash panel insert is equipped with self-diagnosis, which
makes fault finding easier.
1.1 Adapting/renewing dash panel insert

– Select “Guided fault finding” mode in vehicle diagnosis tester .
♦ Body
144 Rep. gr.90 - Gauges, instruments

♦ 01 - On Board Diagnostic capable systems
♦ Dash panel insert
♦ Functions of dash panel insert
♦ Adapting/renewing dash panel insert
1.2 Removing and installing dash panel in‐

sert
Note
Before removing the dash panel insert, the work procedure

“Adapting/replacing dash panel insert” should always be carried
out in order that the data stored in the control unit can be interro‐
gated ⇒ page 144 .
Removing:
– Remove trim on driver side ⇒ General body repairs, interior;
Rep. gr. 68 ; Compartments, covers and trim; Removing and
installing trim on driver side .
– Remove dash panel insert trim ⇒ General body repairs, inte‐
rior; Rep. gr. 68 ; Compartments, covers and trim; Removing
and installing dash panel insert trim .
– Remove securing bolts -arrows- for dash panel insert -1-.
Note
When pulling out dash panel insert, there is no need to separate

the connectors. The connections comprise of one part that is fixed
to the vehicle and are thus separated automatically when the
dash panel insert is pulled out.
– Pull dash panel insert -1- out of dash panel.

Installing:
– After completing installation, check function of dash panel in‐
sert.
1.3 Dash panel insert final control diagnosis

The following components and functions can be checked by way
of dash panel insert final control diagnosis:
♦ Speedometer - G21-
♦ Rev. counter - G5-
♦ Fuel gauge - G1-
♦ Coolant temperature gauge - G3-
♦ Buzzer and gong - H3- (gong activation in dash panel insert)
♦ Turn signal acoustics (turn signal relay activation)
1. Dash panel insert 145

♦ Segment test (during segment test, all segments of the display

unit are activated. The display is successively activated in
white, red, green and blue).
♦ Glow period warning lamp - K29-
♦ Immobiliser warning lamp - K115-
♦ Seat belt warning system warning lamp - K19-
♦ Dual circuit brake system/handbrake system warning lamp -
K7-
♦ Brake pad warning lamp - K32-
♦ Washer fluid low warning lamp - K106-
♦ Reserve fuel warning lamp - K105-
♦ Oil pressure warning lamp - K3-
♦ Oil level warning lamp - K38-
♦ Oil pressure warning buzzer - H11-
Note
Whether above mentioned components or functions can be

checked depends on vehicle equipment.

♦ Body
♦ Dash panel insert
♦ Functions of dash panel insert
♦ Dash panel insert final control diagnosis
1.4 Description of back of dash panel insert
Note
The dash panel insert must not be dismantled. If necessary, the

dash panel insert is renewed as a unit.
Description of back of dash panel insert ⇒ Current flow diagrams,

Electrical fault finding and Fitting locations.
1.5 Pin assignment of connectors on dash

panel insert
Note
The pin assignment on the dash panel insert depends on the ve‐
hicle's equipment, country and engine type.

Pin assignment on dash panel insert ⇒ Current flow diagrams,

Electrical fault finding and Fitting locations.
1.6 Warning lamp symbols in dash panel insert
Note
♦ The assignment of the warning lamps in the dash panel insert depends on vehicle equipment, country and
engine version.
♦ Different versions of dash panel insert are installed depending on vehicle equipment. Therefore, the ar‐
rangement of the warning lamps may differ.
1 - Electromechanical power
steering warning lamp
2 - Exhaust emission warning
lamp (OBD)
3 - Engine control unit warning
lamp (EPC - Electronic Power
Control)
❑ Warning lamp fitted on
vehicles with petrol en‐
gine only
1. Dash panel insert 147

4 - Electronic parking brake warning lamp

5 - Alternator warning lamp
6 - Tyre pressure monitor warning lamp
7 - Left or right turn signal warning lamp (turn signals)
8 - Oil pressure warning lamp
9 - Coolant temperature/coolant level warning lamp
10 - Brake pad wear indicator warning lamp
11 - “Door open” warning lamp
12 - Window washer fluid warning lamp
13 - “Bonnet/rear lid open” warning lamp
14 - Fuel level warning lamp
15 - Engine oil level warning lamp
16 - Anti-lock brake system (ABS) warning lamp
17 - Electronic stabilisation programme (ESP) warning lamp
18 - Handbrake system/brake system warning lamp
19 - Cruise control system (CCS) warning lamp
20 - Fog light warning lamp
21 - Bulb failure warning lamp
22 - Seat belt warning lamp
23 - “Operate foot brake” warning lamp
❑ Warning lamp fitted on vehicles with automatic gearbox only
24 - Airbag / belt tensioner warning lamp
25 - Rear fog light warning lamp
26 - “Fuel tank flap open” warning lamp
27 - Main beam warning lamp

2 Service interval display
2.1 Resetting service interval display

– Resetting service interval display ⇒ Maintenance ; Booklet
21.1
2. Service interval display 149

92 – Windscreen wash/wipe system

1 Windscreen wiper system
Caution
To disconnect and reconnect the battery, the procedure de‐

scribed in the workshop manual should be strictly adhered to
⇒ page 4 .
Note
Self-study programme ⇒ Self-study programme No. 339 ; The
Passat 2006
Self-study programme⇒ Self-study programme No. 340 ; The
Passat 2006 - Electrical System
The wiper motor control unit - J400- and the windscreen wiper
motor - V- are combined to form one unit.
To remove the wiper blades, the wiper arms should be placed in
the “service/winter position”. The “service/winter position” is acti‐
vated within 10 seconds after ignition is switched off by pressing
windscreen wiper lever in “tip wipe” position ⇒ Operating manual
of vehicle .
The wiper motor control unit - J400- is equipped with self-diag‐
nosis, which makes fault finding easier.
1.1 Deactivating APP function of wiper mo‐

tor
The windscreen wiper system is equipped with an APP function
(alternating park position).
With the APP function, the wiper is moved up slightly once it has
reached the lowest position. This occurs every second time the
wiper system is switched off.
To fit the motor crank on the wiper motor, it is necessary for the
motor to be in the lowest park position. To ensure this position is
reached, the APP function must be deactivated.
150 Rep. gr.92 - Windscreen wash/wipe system

Note
♦ The APP function cannot be activated.

♦ After 100 cycles of wiper movement, the APP function is acti‐
vated automatically. This applies to wiper motors on which the
APP function has been deactivated and also to new wiper mo‐
tors.

♦ Body
♦ Onboard supply control unit
♦ Functions
♦ Coding wiper electronics control unit / deactivating APP func‐
tion
Note
Following successful completion of APP function coding / deac‐

tivation, the wiper motor is located in the lower park position after
the next wipe cycle.
1.2 Removing and installing windscreen

wiper system
1. Windscreen wiper system 151

♦ Release lever - 80-200-
♦ Puller - T10369-
1.2.1 Removing windscreen wiper system

– Deactivate APP function ⇒ page 150 .
– Allow wiper to move to park position and then switch ignition
off.
Caution

⇒ page 4 .
1.2.2 Removing wiper arms

– Lever off the cover caps -arrows- using a suitable screwdriver.

– Slide legs of puller - T10369/1- -2- under wiper arm -4- as

shown in the illustration.
Caution
The wiper shaft may be damaged.

Always use the thrust piece -3- to loosen the wiper arm.
– Turn thrust bolt -1- of puller clockwise until thrust piece -3-
comes into contact with wiper shaft. Turn thrust bolt -1- of
puller clockwise using a 6 mm Allen key until wiper arm -4- is
loosened off shaft.
– Remove puller and wiper arm.
– Repeat this procedure for the front passenger side if neces‐
sary.
1.2.3 Removing plenum chamber cover

Remove plenum chamber cover ⇒ General body repairs, exterior;
Rep. gr. 64 ; Flush bonded windows; Assembly overview - ple‐
num chamber cover; Removing plenum chamber cover .
1.2.4 Removing wiper frame with linkage and

wiper motor
Note
To remove wiper frame with linkage and wiper motor, first remove
wiper arms and plenum chamber cover.

– Unclip wiring retainer -3- out of retaining plate of wiper frame.
– Remove lower securing nut with washer -4-.
– Remove upper securing bolts -1-.
– Remove wiper frame with linkage and wiper motor from vehi‐
cle.
1.2.5 Removing wiper motor from wiper frame

– Lever ball head -arrow- of linkage -1- off motor crank using
release lever - 80-200- or a suitable screwdriver.

– Remove hexagon nuts -1-.

– Pull motor crank -2- off wiper motor shaft.
– Unscrew securing bolts -arrows- and remove retaining strip
-3-.
– Remove wiper motor with control unit from wiper frame down‐
wards.
1.2.6 Installing wiper motor in wiper frame

– Install wiper motor with control unit to wiper frame, ensuring it
seats correctly in cut-outs -arrows- in linkage.
– Fit retaining plate -1- and install securing bolts -arrows-.

– Tighten securing bolts -arrows- to specified torque
⇒ page 185 .

– Place motor crank -2- on shaft of wiper motor.

Various versions of retaining plate are used from two different
manufactures.
– Establish which version of retaining plated is used by checking
manufactures embossing on plate.
Note
If there is no embossing on the wiper linkage, look on the wiper

motor to determine the manufacturer.
– Set distance -a- between stop on retaining plate -3- and motor
crank -2- to following dimension:
– Bosch: dimension -a- = 2.7 mm
– Mitsuba: dimension -a- = 6.4 mm
– Place crank arm onto shaft of wiper motor and secure with nut
-1-.
– Tighten securing nut -1- to specified torque ⇒ page 185 .
– Press ball head -arrow- of linkage -1- onto motor crank.
1.2.7 Installing windscreen wiper system

– Position wiper motor with wiper frame and linkage in vehicle.
– Fit upper securing bolts -1-.
– Fit lower securing nut with washer -4-.
– Tighten all threaded connections to specified torques
⇒ page 185 .
– Fit connector -2- to wiper motor connection until it engages.
– Clip wiring retainer -3- into hole in retaining plate.
– Install plenum chamber cover and plenum chamber seal in
reverse order of removal.
– Install wiper arms ⇒ page 155 .
1.2.8 Checking windscreen wipers

The windscreen wipers can be tested using the final control di‐
agnosis function of the onboard supply control unit - J519-
⇒ page 424 .
1.3 Removing and installing wiper arms


Removing:
Removing wiper arms ⇒ page 152 .
Installing:
Note
Securing nuts of wiper arms -arrows- are not tightened to speci‐

fied torque until after wiper blade park position has been adjusted.
– Power wiper motor to park position.

– For this, switch on ignition and push steering column lever
down once briefly (tip wipe).
– Switch ignition off again once wiper motor has stopped.
– Place the wiper arms in approximate park position on the wiper
arm shafts and tighten securing nuts -arrow- hand tight.
– Adjust windscreen wiper blade park position ⇒ page 156 .
1.4 Adjusting wiper blade park position

Note
On RHD vehicles, the wiper blades are a mirror image of those

on LHD vehicles.
– Deactivate APP function ⇒ page 150 .

– Power wiper motor to park position and then switch ignition off.
– Now adjust windscreen wiper blade park position.

Driver side:
Distance -A- between middle of wiper blade and lower edge of
windscreen should be 39 mm.
– If necessary, adjust wiper blade park position by moving wiper
arm.
– Tighten securing nut to specified torque ⇒ page 185 .
Front passenger side:

Distance -B- between wiper blade and upper edge of plenum
chamber cover should be 14 mm.
– If necessary, adjust wiper blade park position by moving wiper
arm.
– Tighten securing nut to specified torque ⇒ page 185 .
1.5 Removing and installing aerodynamic

wipers
To remove the wiper blades, the wiper arms should be placed in
the “service/winter position”. The “service/winter position” is acti‐
vated within 10 seconds after ignition is switched off by pressing
the windscreen wiper lever in position “tip wipe”.
⇒ Operating Manual of vehicle
Removing:
Note
♦ Driver and front passenger wiper blades must not be inter‐

changed during installation.
♦ The aero wipers are very flexible. To lift the wiper blades off
the windscreen, touch them only in the area in which the wiper
blades are attached to the wipers.
– Place wiper arms in “service/winter position”.

– Lift up wiper arm.
– Press button -1- and pull wiper blade mounting -3- out of wiper
arm -2- to stop.

– Swing wiper blade, as shown in illustration, and pull wiper

blade mounting -3- out of wiper arm -2- in direction of arrow.
Installing:
– Push wiper blade mounting -3- onto wiper arm -2- to stop.
– Ensure button -1- has locked correctly into wiper arm -2-.
– Carefully fold wiper arm back down onto windscreen.
1.5.1 Removing and installing wiper rubber on

aero wiper
Note
Refer to chapter »Distinguishing features of aero wiper blades«

in Workshop Manual “Electrical System, General Information”. A
– Remove aero wiper blade ⇒ page 157 .

– Check to see on which side wiper rubber cannot be pushed
into guide.
– On the side that cannot be pushed into the guide, carefully
lever off the cap -1-.

– Using a suitable screwdriver, open the wiper rubber stop -A-

by bending up.
– Now change wiper rubber.
Note
Ensure that wiper rubber is seating correctly in wiper blade

guides.
– Push wiper rubber stop -A- back down using a suitable screw‐
driver until wiper rubber can no longer be moved in the guide.
– Fit the new cap -1- and check that it is properly attached.
– Fit aero wiper blade again ⇒ page 157 .
– Check that wiper blade functions properly.
1.6 Removing and installing rain and light

sensor - G397-
If an intact rain and light sensor - G397- is removed from its re‐
taining plate on the windscreen (e.g. renewing a windscreen) it
can be subsequently reinstalled. Store the removed rain and light
sensor - G397- in a dust-free location until reinstallation and en‐
sure the silicone contact pad is not soiled.
Removing:
– Remove the interior mirror ⇒ General body repairs, interior;
Rep. gr. 68 ; Removing and installing interior mirror.
– Unclip cable cover, which runs over rain and light detector
sensor - G397- .

– Disconnect connector -1- from rain and light sensor - G397-

-2-.
– Use, for example, a suitable blade-type screwdriver to prise

the rain and light detector sensor - G397- -1- out of the retain‐
ing plate -2- on the windscreen.
Note
On removal, take care to prise out the entire rain and light sensor
- G397- and not just the upper shell of the rain and light sensor -
G397- .
Installing:
– Thoroughly clean the windscreen inside the retaining plate
with isopropanol (isopropyl alcohol).
– Remove the protective cap on the new rain and light sensor -
G397- .
Note
♦ The surface (contact pad) of the rain and light sensor - G397-
must not be soiled on installation.
♦ If the surface (coupling pad) of the rain and light sensor - G397-
is soiled, it may be possible to clean it by “bonding on” and
then “pulling off” one or more adhesive strips.
– Seat the rain and light sensor - G397- -1- in the retaining plate
-2- on the windscreen and press it on until secure.
Note
There must not be any air bubbles between the windscreen and
the contact pad of the rain and light sensor - G397- following in‐
stallation.

– Reconnect the connector -1- and secure the rain sensor -2- by
installing the cable cover.

2 Windscreen washer system
Note
♦ The windscreen washer system function can be tested using

the final control diagnosis of the onboard supply control unit -
J519- .

Passat 2006
The onboard supply control unit features self-diagnosis to facili‐
tate fault finding.
2.1 Assembly overview - windscreen wash‐

er system
Note
The window washer fluid reservoir may be of a single chamber or

double chamber design depending on equipment installed. The
following illustrations show the double chamber saloon version of
the windscreen and headlight washer system.

1 - Windscreen washer system

spray jets
⇒ page 169
❑ Adjusting ⇒ page 170
2 - Angled connection piece
❑ Connection to wind‐
screen spray jet
❑ Overview of hose cou‐
plings for washer fluid
lines ⇒ page 183
3 - Y-piece
❑ Distribution of washer
fluid line to windscreen
spray jets
4 - Upper part of window wash‐
er system and headlight wash‐
er system reservoir.
⇒ page 165
single chamber wind‐
screen washer reservoir
⇒ page 164
5 - Lower part of window wash‐
⇒ page 166
6 - Washer pump - V5-
❑ Windscreen and rear
window washer pump -
V59- for Variant
⇒ page 168
❑ Checking windscreen and rear window washer pump - V59- ⇒ page 424
❑ Connection to windscreen washer pump - V5-
❑ Overview of hose couplings for washer fluid lines ⇒ page 183
8 - Windscreen washer fluid level sender - G33-
❑ Removing and installing ⇒ page 169
9 - Hose
❑ Hose repair ⇒ page 184
2.2 Removing and installing washer fluid

reservoir
The window washer fluid reservoir may be of a single chamber or
double chamber design depending on equipment installed.
Windscreen washer reservoir is of single chamber design on ve‐
hicles with no headlight washer system.
♦ Removing and installing windscreen washer reservoir (single
chamber version) ⇒ page 164
2. Windscreen washer system 163

Washer fluid reservoir is of double chamber design on vehicles

with windscreen and headlight washer systems.
♦ Removing and installing upper part of reservoir for window and
headlight washer system ⇒ page 165 .
♦ Removing and installing lower part of reservoir for window and
headlight washer system ⇒ page 166 .
2.2.1 Removing and installing windscreen

washer reservoir (single chamber ver‐
sion)
Note
♦ The following illustration shows the saloon version of the win‐

dow washer system reservoir with installed washer pump -
V5- . In this location on the Variant the windscreen and rear
window washer pump - V59- with two hose connections is in‐
stalled.
♦ The connections to the pump and hose lines are colour-coded
in order to prevent the washer fluid lines being incorrectly con‐
nected to the front and rear washer fluid pump - V59- . The
hose fittings must be connected to the correct colour-coded
pump connections during installation.

Removing:
– Remove front bumper cover ⇒ General body repairs, exterior;
Rep. gr. 63 ; Removing and installing front bumper.
– Remove front right wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Removing and installing wheel
housing liner.
– Remove right headlight ⇒ page 188 .
exterior; Rep. gr. 50 ; Lock carrier.
– Unscrew fuel filter bracket and place filter to side with lines still
connected.
– Unclip all lines from reservoir for windscreen and headlight
washer systems.

– Remove securing bolt -1-.

Note
Depending on equipment fitted, there may be a requirement to

release retainers for pipework blocking access to securing bolt
-2-.
– Remove securing bolt -5- from wheel housing.

– Pull hose connection off washer pump - V5- -3- and collect
escaping washer fluid in a suitable container.
– Release and disconnect connector on washer pump - V5-
-3-.
– Remove window washer system reservoir -4- from vehicle up‐
wards.
Installing:
following:
Note
When installing window washer system reservoir, ensure that

lines in the vicinity of the reservoir are not squashed and are clip‐
ped back into their original position on the reservoir.

⇒ page 185 .
2.2.2 Removing and installing upper part of

reservoir for window and headlight
washer system
Removing:
Rep. gr. 63 ; Removing and installing front bumper.
pairs, exterior; Rep. gr. 66 ; Removing and installing wheel
housing liner.

– Remove right headlight ⇒ page 188 .

exterior; Rep. gr. 50 ; Lock carrier.
– Unscrew fuel filter bracket and place filter to side with lines still
connected.
– Unclip all lines from upper part of reservoir -4-.
– Remove securing bolts -1-, -2- and -3-.
Note
Depending on equipment fitted, there may be a requirement to

release retainers for pipework blocking access to securing bolt
-2-.
– Remove securing bolt -7- from wheel housing.

– Pull upper part -4- of reservoir vertically upwards out of rubber
grommet -6- of lower part -5- of reservoir.
– Lift upper part of reservoir upwards out of vehicle.
Installing:
following:
– Insert upper part -4- of reservoir vertically into rubber grommet

-6- of lower part of reservoir, from above.
Note
♦ Before installation, moisten both reservoir halves of the rubber

grommets -6- with for example a rubber and plastic compatible
lubricant (e.g. polyethylene glycol).
♦ Ensure when installing upper part of reservoir for window and
headlight washer system that lines in the vicinity of the reser‐
voir are not squashed and are clipper back into their original
position on the reservoir.

⇒ page 185 .
– On completion of installation work, bleed headlight washer
system ⇒ page 182 .
2.2.3 Removing and installing lower part of

reservoir for window and headlight
washer system
Note
The following illustration shows the saloon version of the window

washer system reservoir with installed washer pump - V5- . In this
location on the Variant the windscreen and rear window washer
pump - V59- with two hose connections is installed.

Note
The connections to the pump and hose lines are colour-coded in

order to prevent the washer fluid lines being incorrectly connected
to the front and rear washer fluid pump - V59- . The hose fittings
must be connected to the correct colour-coded pump connections
during installation.

Removing:
– Remove upper part of reservoir for windscreen and headlight
washer system ⇒ page 165 .
– Unclip all lines from lower part of reservoir -8-.
– Release and disconnect connector -1- for headlight washer
system pump - V11- -2-.
– Release and disconnect connector -5- for washer pump - V5-
-3-.
– Release and disconnect connector -6- for windscreen washer
fluid level sender - G33- -7-.
– Pull hose connection -4- off washer pump - V5- -3- and collect
– Remove securing bolt -1- from lower part of reservoir for win‐
dow and headlight washer system -2-.
– Pull lower part of reservoir -2- forwards out of grooves of re‐
taining plate -3-.

Installing:
following:
The guides on the inner side of the lower part of the reservoir
-2- must be inserted into the grooves of the retainer -3- on the
vehicle when installing.
⇒ page 185 .
– Install upper part of reservoir for window and headlight washer
2.3 Removing and installing washer pump -

V5- or windscreen and rear window
washer pump - V59-
Note
The following illustration shows the saloon version of the double

chamber reservoir of the window washer system with installed
washer pump - V5- . In this location on the Variant the windscreen
and rear window washer pump - V59- with two hose connections
is installed. Removing and installing the windscreen and rear win‐
dow washer pump - V59- is performed in the same manner.
Note
The connections to the pump and hose lines are colour-coded in

order to prevent the washer fluid lines being incorrectly connected
to the front and rear washer fluid pump - V59- . The hose fittings
must be connected to the correct colour-coded pump connections
during installation.
Removing:
– Loosen front bumper ⇒ General body repairs, exterior; Rep.
gr. 63 ; Front bumper .
– Pull hose connection -4- off washer pump - V5- -3- and collect
– Pull windscreen washer pump - V5- -3- upwards out of reser‐
voir and separate connector -5-.
Installing:
following:

2.3.1 Checking windscreen and rear window

washer pump - V59-
The windscreen and rear window washer pump - V59- can be
checked using final control diagnosis for onboard supply control
unit - J519- ⇒ page 424 .

washer fluid level sender - G33-
The windscreen washer fluid level sender - G33- is mounted on
the windscreen and the headlight washer system reservoir before
the front right wheel housing.
Removing:
Rep. gr. 63 ; Front bumper .
– Release and disconnect connector -6- on windscreen washer
fluid level sender - G33- -7-.
– Pull windscreen washer fluid level sender - G33- -7- out of its
rubber seal.
Installing:
following:

washer system spray jets
Removing:
– Push spray jet upwards -arrow A- and pull it downwards out of
bonnet -arrow B-.
– Pull hose -1- off spray jet and disconnect connector -2- for
heated spray jet.
Installing:
– Fit connector and hose on spray jet.
– Push spray jet in installation hole until it is heard to lock in
place.
– Adjust spray jets ⇒ page 170 .

2.6 Adjusting windscreen washer system

spray jets
Caution
♦ Danger of causing damage.

♦ The spray jet may be damaged.
♦ Do not use objects to clean the spray jets!
Note
If impurities in the spray jet cause an uneven spray field, remove

the spray jet and flush through with water against the spraying
direction. Purging with compressed air against the spraying di‐
rection is then permitted. Do not use objects to clean the spray
jets!
Adjusting windscreen washer system spray jets ⇒ Maintenance ;

Booklet 21.1 .

3 Rear window wiper system
Note
Passat 2006
The onboard supply control unit features self-diagnosis to facili‐
tate fault finding.
Caution

⇒ page 4 .
3.1 Assembly overview - rear window wiper system
3. Rear window wiper system 171

1 - Cover cap
2 - 13 mm hexagon collar nut
❑ 12 Nm
3 - Wiper arm
❑ Removing ⇒ page 172
❑ Installing ⇒ page 173
❑ Adjusting rear window
wiper park position
⇒ page 174 .
4 - Seal
5 - Spray jet
❑ Renewing ⇒ page 177
❑ Adjusting ⇒ page 177
6 - Rear window wiper motor
⇒ page 173
7 - M6 hexagon nut with wash‐
er
❑ 8 Nm
8 - Rubber ring
9 - Spacer
10 - Wiper blade
aerodynamic wipers
⇒ page 174 .
3.2 Removing rear window wiper
3.2.1 Removing wiper arm

– To place wiper motor in its park position, switch rear window
wiper on and off with ignition on.
– Lift up cover -1- of rear window wiper and unclip cover.
– Loosen 13 mm hexagon nut -arrow- without removing it com‐
pletely.
Note
Aerodynamic wipers are very flexible. To lift the wiper blade off
the rear window, grasp it only in the area in which the wiper blade
is attached to the wiper.
– Lift up wiper arm and free off from taper by rocking from side
to side.
– Unscrew hexagon bolt -arrow- and remove from wiper arm.

3.2.2 Removing and installing rear window

wiper motor
Caution

⇒ page 4 .
Removing:
Remove wiper arm before removing rear window wiper motor
⇒ page 172 .
– Remove lower rear lid trim ⇒ General body repairs, interior;
Rep. gr. 70 ; Trim; Rear lid; Removing and installing on Var‐
iant .
– Release hose connection -2- by pulling securing ring upwards
and pull hose off connection on rear wiper motor
– Unscrew hexagon nuts -arrows-.
– Pull motor carefully off rear lid.
Installing:
following:
– Before installing rear wiper motor, moisten inner side of rubber
seal with for example a rubber and plastic compatible lubricant
(e.g. polyethylene glycol).
– Check seal is seated correctly in opening of rear window. Mark

-1- on seal must align with mark -2- on rear window.
3.2.3 Installing wiper arm

– With ignition switched on, switch rear window wiper on and off
to run wiper motor to its rest position.
– Fit wiper arm in approximate park position on wiper arm shaft
and tighten securing nut -arrow- by hand.
– Adjust rear window wiper park position ⇒ page 174 .

3.3 Adjusting rear window wiper park posi‐

tion

Gap -x- between end of wiper blade -1- and lower edge of window
-2- must be 23 mm.
– If necessary, adjust rear window wiper park position by moving
wiper arm on shaft.
Removing wiper arm ⇒ page 172
⇒ page 185 .
3.4 Removing and installing aerodynamic

wipers
Note
Aerodynamic wipers are very flexible. To lift the wiper blade off
the rear window, grasp it only in the area in which the wiper blade
is attached to the wiper.
Removing:
– Pull wiper arm -2- away from windscreen.
– Pull wiper blade mounting -1- out of wiper arm -2- -arrow-.

– Remove wiper blade fitting -1- from wiper arm shaft -2-.
Installing:
– Fit the wiper blade fitting -1- onto the shaft -2- of the wiper arm
-3-.
– Push on the wiper blade fitting until it engages in the wiper
arm.
– Carefully fold wiper arm back down onto rear window.

4 Rear window washer system
Note
♦ The function of the rear window washer system can be tested

using the final control diagnosis of the onboard supply control
unit - J519- .

Passat 2006
The onboard supply control unit - J519- is equipped with self-di‐
agnosis, which makes fault finding easier.
4.1 Assembly overview - rear window washer system

❑ Point of separation, pas‐
senger compartment
wiring harness to rear lid
wiring harness
lines ⇒ page 183
2 - Spray jet for rear window
washer system
❑ Renewing spray jet
⇒ page 177
❑ Adjusting spray jet
⇒ page 177
❑ Connection to spray jet
for rear window washer
system
lines ⇒ page 183
4 - Upper part of window wash‐
⇒ page 165
single chamber wind‐
screen washer reservoir
⇒ page 164
5 - Lower part of window wash‐

⇒ page 166
❑ Connection to windscreen and rear window washer pump - V59- .
❑ Overview of hose couplings for washer fluid lines ⇒ page 183
7 - Windscreen and rear window washer pump - V59-
9 - Hose
❑ Hose repair ⇒ page 184
4.2 Renewing spray jet

Removing:
– To place wiper motor in its park position, switch rear window
wiper on and off with ignition on.
– Lift up cover cap of rear window wiper arm.
– Pull spray jet out of wiper arm shaft using suitable pliers
-arrow-.
Installing:
– Push spray jet onto stop in wiper arm shaft with spray jet
opening facing upwards.
– Adjust spray jet ⇒ page 177 .
4.3 Adjusting spray jet
Caution

⇒ Maintenance ; Booklet 21.1 .
4. Rear window washer system 177

5 Headlight washer system
Note
♦ The function of the headlight washer system can be tested

using the final control diagnosis of the onboard supply control
unit - J519- .
Passat 2006
tions
Every fifth time the windscreen washer system is activated the
headlights are also washed if the windscreen wiper lever on the
steering wheel is pulled for at least 1.5 seconds - provided either
dipped beam or main beam are switched on.
The “active time” of the headlight washer system can be adjusted
from between 0 and 12.75 seconds ⇒ page 423 .
To guarantee sound functioning, the headlight washer system
must be vented following assembly work or when activated for the
first time ⇒ page 182 .
5.1 Assembly overview - headlight washer system

1 - Pop-up cylinder with right

spray jet
spray jet assembly
⇒ page 181
❑ Adjusting spray jets
⇒ page 181
pop-up cylinder
⇒ page 180
2 - Pop-up cylinder with left
spray jet
spray jet assembly
⇒ page 181
❑ Adjusting spray jets
⇒ page 181
pop-up cylinder
⇒ page 180
3 - Angled piece
❑ Connection to left spray
jet pop-up cylinder
❑ Washer fluid line hose
couplings ⇒ page 183
4 - T-piece
❑ Distribution of washer
fluid to spray jets on
headlight washer sys‐
tem
5 - Angled piece
❑ Connection to right
spray jet pop-up cylin‐
der
❑ Washer fluid line hose couplings ⇒ page 183
6 - Upper part of window washer system and headlight washer system reservoir.
❑ Removing and installing single chamber windscreen washer reservoir ⇒ page 164
7 - Hose
8 - Angled piece
❑ Connection to headlight cleaning system pump
9 - Headlight washer system pump - V11-
11 - Lower part of window washer system and headlight washer system reservoir.
5. Headlight washer system 179

5.2 Removing and installing headlight

washer system pump - V11-
The headlight washer system pump - V11- is mounted on the
washer fluid reservoir in the right-hand wheel housing.
Removing:
– Disconnect connector -1- and pull pump -2- upwards out of
reservoir.
– Drain any escaping fluid in a suitable container.
Installing:
following:
5.2.1 Checking headlight washer system

pump - V11-
The headlight washer system pump - V11- can be checked using
final control diagnosis for onboard supply control unit - J519-
⇒ page 424 .
5.3 Removing and installing pop-up cylinder

with spray jet
Note
The illustrations show removal and installation of the front right

pop-up cylinder. The removal of the left pop-up cylinder is basi‐
cally a mirror image.

Removing:
– Pull spray jets together with cover cap -1- out of bumper cover
to stop.
– Unclip cap -1- from both sides of mounting -arrow- on spray
jet retainer.
– Hold down securing clip -arrow- and pull hose connection -3-
off from pop-up cylinder.
– Remove securing bolts -1-.
– Remove pop-up cylinder -2- from bumper cover.
Installing:
following:
– Tighten securing nuts -1- to specified torques ⇒ page 185 .
5.4 Removing and installing spray jet as‐

sembly
Note
The pop-up cylinder with spray jet is assembled as one compo‐

nent and cannot be dismantled. If repair is required, the entire
pop-up cylinder with spray jet must be renewed.
5.5 Adjusting spray jets
Caution

5. Headlight washer system 181

5.6 Bleeding headlight washer system

To guarantee sound functioning, the headlight washer system
must be bled following assembly work or when operated for the
first time.
– Fill washer fluid reservoir.
– Start engine.
– Switch headlights to “ON”.
– Operate headlight washer system several times (3-5 times, 3
seconds each time).
– Repeat this bleeding procedure, if necessary until the pop-up
cylinders and spray jets are functioning soundly.
5.7 Adapting headlight washer system

The “active time” (headlight cleaning time) of the headlight washer
system can be adjusted between 0 and 12.75 seconds.
Adapting headlight washer system ⇒ page 427 .

6 Washer fluid line hose couplings

6.1 Headlight washer system

6. Washer fluid line hose couplings 183

7 Hose repair

8 Specified torques: window wash/

wipe system
8.1 Specified torques for windscreen wash/

wipe system
Wiper motor to wiper M6 9 Nm
frame
Motor crank to wiper mo‐ M8 17 Nm
tor shaft
Wiper frame to body (up‐ M6 8 Nm
per bolts)
Wiper frame to body (low‐ M6 5 Nm
er nuts)
Windscreen wiper arms M8 20 Nm
to wiper motor shaft
Securing bolts for wind‐ M6 8 Nm
screen and headlight
washer system reservoir
8.2 Specified torques for rear window wash/

wipe system
Securing nuts for wiper M6 8 Nm
motor to rear lid
Securing nut for wiper M8 12 Nm
arm to wiper motor shaft
8.3 Specified torques for headlight washer

system
Securing bolts for pop-up 2.8 Nm
cylinder with left spray jet
in bumper
8. Specified torques: window wash/wipe system 185

94 – Lights, bulbs, switches - exterior

1 Headlight
Note
♦ Before working on headlights, always switch off the headlights

and disengage the ignition key or start button by moving to
position 0 (locked).
♦ When dealing with complaints, it is absolutely essential that
the function and operation of the lighting system are first un‐
derstood.
Passat 2006
The vehicle is fitted with headlights from two different manufac‐
turers:
♦ Hella
♦ Valeo
Installation and removal of the headlights and associated com‐
ponents are the same except for installation and removal of the
control motors and bulbs.
The onboard supply control unit has a self-diagnostic function,
which makes fault finding on headlights easier.
1.1 Assembly overview - headlight
Note
The exploded view shows the control motors of both headlight

manufacturers, as the removal and installation operations differ.
186 Rep. gr.94 - Lights, bulbs, switches - exterior

1 - Left headlight range control

motor - V48- or right headlight
range control motor - V49-
❑ Headlight manufacturer
Hella
⇒ page 207
2 - Retaining ring
3 - Left headlight range control
motor - V48- or right headlight
❑ Headlight manufacturer
Valeo
⇒ page 208
4 - Retaining ring
5 - Body aperture
6 - Cover cap
7 - Left headlight main beam
bulb - M30- or right headlight
main beam bulb - M32-
❑ Bulb H7 12 V, 55 W
❑ Renewing, headlight
manufacturer Hella
⇒ page 194
❑ Zero
8 - Securing bolts
❑ 2 Nm
9 - Securing bolts
❑ 8 Nm
10 - Adjustment bushes
❑ Correcting installation position of headlight ⇒ page 190
11 - Headlight
❑ Correcting installation position of headlight ⇒ page 190
❑ Repairing headlight retaining tabs ⇒ page 211
❑ Converting headlights to drive on the left or the right (manufactured by Hella) ⇒ page 215
❑ Converting headlights to drive on the left or the right (manufactured by Valeo) ⇒ page 218
12 - Left side light bulb - M1- or right side light bulb - M3-
❑ RoW version: bulb 12 V, W 5 W
❑ Canada and USA version: bulb 12 V, WY 5 W.
❑ Renewing, headlight manufacturer Hella ⇒ page 197
❑ Renewing, headlight manufacturer Valeo ⇒ page 204
13 - Cover cap
14 - Left headlight dipped beam bulb - M29- or right headlight dipped beam bulb - M31-
❑ Bulb H7 12 V, 55 W
❑ Renewing, headlight manufacturer Hella ⇒ page 191
❑ Renewing, headlight manufacturer Valeo ⇒ page 199
15 - Cover cap
1. Headlight 187
1.2.1 Removing headlight
Note
♦ There is no requirement to disconnect the battery earth strap.

♦ The illustrations show removal and installation of the left head‐
light.
♦ The replacement of the left headlight and the right headlight is
analogue.
♦ If a headlight is removed, it should always be adjusted follow‐
ing installation ⇒ Maintenance ; Booklet 21.1 .
♦ If a headlight with gas discharge bulbs is removed, the basic
setting of the headlight should always be checked when rein‐
stalling ⇒ Maintenance ; Booklet 21.1 .

Note
During removal and installation, place the radio remote control

ignition key in the vehicle's interior to prevent the doors from lock‐
ing and poss. independent activation of the “Coming Home /
Leaving Home ” functions.
– Release multi-pin connector -arrow- and disconnect.

gr. 66 ; Mouldings and trim panels; Removing and installing
radiator grille.
– Remove securing screws -arrows- and remove guide profile

-1-.

– Remove securing screws -arrows- from top of headlight.
– Remove securing screws -arrows- from base of headlight.

– Remove headlight from body aperture.
1.2.2 Installing headlight


– Tighten all securing bolts to specified torque settings
⇒ page 335 .
– Check headlight installation position is central, i.e. shut lines/
gaps are equal around headlight.
If the shut lines/gaps around the headlight are uneven, the instal‐
lation position must be adjusted ⇒ page 190 .
– Check headlight functions.
Note
If a headlight is removed, it should always be adjusted following

installation.
1. Headlight 189
– Check headlight setting and adjust headlight as necessary

1.3 Adjusting headlight installation position

Note
♦ The illustrations show the left headlight.

♦ The adjustment of the left headlight and the right headlight is
analogous.
If it transpires during checking of the installation position that the

shut lines/gaps between headlight and body are uneven, the in‐
stallation position must be adjusted.
gr. 66 ; Mouldings and trim panels; Removing and installing
radiator grille.
– Loosen securing screws -arrows- at top of headlight.

– Loosen securing screw -arrows- on base of headlight.
– Adjust flush fit with body by screwing in or screwing out ad‐

justment bushing -arrow- at bottom left or bottom right of
headlight.
– Tighten all threaded connections to specified torques
⇒ page 335 .
– Check and, if necessary, readjust headlight to ensure gaps are
even all round.
– Install front bumper cover ⇒ General body repairs, exterior;
– Install radiator grille ⇒ General body repairs, exterior; Rep.
gr. 66 ; Mouldings and trims; Removing and installing radiator
grille .
Note
If a headlight is removed or adjusted to fit more accurately to the

vehicle body, it must be aligned following such measures.

1.4 Renewing headlight bulbs, headlight

manufacturer Hella
1.4.1 Renewing headlight dipped beam bulb
Note
The left headlight dipped beam bulb - M29- and the right headlight
dipped beam bulb - M31- can be checked by the final control di‐
agnosis for the onboard supply control unit - J519- .
Removing:
1. Headlight 191
Note
♦ During removal and installation, place the radio remote control

ignition key in the vehicle's interior to prevent the doors from
locking and poss. independent activation of the “Coming
Home / Leaving Home ” functions.
♦ It may be necessary to remove adjacent components at the
respective headlight when replacing the headlight dipped
beam bulb.
♦ The components to be removed (engine-specific) for replace‐
ment of headlight dipped beam bulb are indicated in the fol‐
lowing tables.
Vehicles with petrol en‐ Renewing left headlight dipped beam Renewing right headlight dipped beam
gine bulb - M29- bulb - M31-
Dis‐ En‐ Engine
place‐ gine
ment code
1.6 l BSE 75 kW -1) 1) -1) 1)
BSF 75 kW -1) 1) -1) 1)
BLF 85 kW -1) 1) -1) 1)
2.0 l BLR 110 kW -1) 1) -1) 1)
BLX 110 kW -1) 1) -1) 1)
BVY 110 kW -1) 1) -1) 1)
AXX 147 kW -1) 1) -1) 1)
BPY 147 kW -1) 1) -1) 1)
3.2 l AXZ 184 kW -1) 1) -1) 1)
3.6 l BLV 206 kW -1) 1) -1) 1)
1) No additional work required.
Vehicles with diesel en‐ Renewing left headlight dipped beam Renewing right headlight dipped beam
Dis‐ En‐ Engine
place‐ gine
ment code
1.9 l BKC 77 kW -2) 2) -2) 2)
BLS 77 kW -2) 2) -2) 2)
2.0 l BMA 100 kW -2) 2) -2) 2)
BKP 103 kW -2) 2) -2) 2)
BMP 103 kW -2) 2) -2) 2)
BMR 125 kW -2) 2) -2) 2)
2.5 l BKX 132 kW -2) 2) -2) 2)

Note
♦ The following figures show renewal of the dipped beam bulb

for the right headlight.
♦ Renewal of the left headlight dipped beam bulb - M29- and the
right headlight dipped beam bulb - M31- is analogue.
– Remove cover cap -1-.
– Turn bulb holder with headlight dipped beam bulb -1- in

-direction of arrow- and pull it out of headlight as far as wiring
allows.
– Pull headlight dipped beam bulb -2- in direction of -arrow- out

of bulb holder -1-.
Installing:
Note
♦ When installing cover cap, ensure that it seats properly. The

ingress of water will lead to permanent damage to the head‐
light.
♦ Do not touch bulb glass when fitting bulbs. Fingers leave
traces of grease on the glass, which evaporate when the bulb
is switched on and cause the glass to cloud over.
1. Headlight 193
– Insert headlight dipped beam bulb into bulb holder so that lug
-1- of headlight dipped beam bulb is in contact with guide -2-
of bulb holder.
– Insert bulb holder with headlight dipped beam bulb -1- into
headlight and turn bulb holder with headlight dipped beam
bulb in direction of -arrow-.
– Install cover cap again.
1.4.2 Renewing headlight main beam bulb
Note
The left headlight main beam bulb - M30- and the right headlight
main beam bulb - M32- can be checked by the final control diag‐
nosis for the onboard supply control unit - J519- .
Removing:
Note

♦ To renew the headlight main beam bulb, it may be necessary
to remove components adjacent to the respective headlight.
♦ The components to be removed (engine-specific) for headlight
main beam bulb renewal are indicated in the following tables.
Vehicles with petrol en‐ Renewing left headlight main beam bulb Renewing right headlight main beam
gine - M30- bulb - M32-
Dis‐ En‐ Engine
place‐ gine
ment code
1.6 l BSE 75 kW -1) 3) -1) 3)
BSF 75 kW -1) 3) -1) 3)
BLF 85 kW -1) 3) -1) 3)

Dis‐ En‐ Engine
place‐ gine
ment code
2.0 l BLR 110 kW -1) 3) -1) 3)
BLX 110 kW -1) 3) -1) 3)
BVY 110 kW -1) 3) -1) 3)
AXX 147 kW -1) 3) -1) 3)
BPY 147 kW -1) 3) -1) 3)
3.2 l AXZ 184 kW -1) 3) -1) 3)
3.6 l BLV 206 kW -1) 3) -1) 3)
Vehicles with diesel en‐ Renewing left headlight main beam bulb Renewing right headlight main beam
Dis‐ En‐ Engine
place‐ gine
ment code
1.9 l BKC 77 kW -2) 4) -2) 4)
BLS 77 kW -2) 4) -2) 4)
2.0 l BMA 100 kW -2) 4) -2) 4)
BKP 103 kW -2) 4) -2) 4)
BMP 103 kW -2) 4) -2) 4)
BMR 125 kW -2) 4) -2) 4)
2.5 l BKX 132 kW -2) 4) -2) 4)
Note
♦ The following figures show renewal of the main beam bulb for
the right headlight.
♦ Renewal of the left headlight main beam bulb - M30- and the
right headlight main beam bulb - M32- is analogue.
1. Headlight 195
– Turn bulb holder with headlight main beam bulb -1- in

-direction of arrow- and pull it out of headlight as far as wiring
allows.
– Pull headlight main beam bulb -2- in direction of -arrow- out of

bulb holder -1-.
Installing:
Note

light.
– Insert headlight main beam bulb into bulb holder so that lug
-1- of headlight main beam bulb is in contact with guide -2- of
bulb holder.
– Insert bulb holder with headlight main beam bulb -1- into head‐
light and turn bulb holder with headlight main beam bulb in
-direction of arrow-.
– Install cover cap again.

1.4.3 Renewing side light bulb
Note
The left side light bulb - M1- and the right side light bulb - M3- can
be checked by the final control diagnosis for the onboard supply
control unit - J519- .
Removing:
Note

♦ To renew side light bulb, it may be necessary to remove com‐
ponents adjacent to the respective light.
♦ The components to be removed (engine-specific) for the re‐
placement of the side light bulb are indicated in the following
tables.
Vehicles with petrol en‐ Renewing left side light bulb - M1- Renewing right side light bulb - M3-
gine
Dis‐ En‐ Engine
place‐ gine
ment code
1.6 l BSE 75 kW -1) 5) -1) 5)
BSF 75 kW -1) 5) -1) 5)
BLF 85 kW -1) 5) -1) 5)
2.0 l BLR 110 kW -1) 5) -1) 5)
BLX 110 kW -1) 5) -1) 5)
BVY 110 kW -1) 5) -1) 5)
AXX 147 kW -1) 5) -1) 5)
BPY 147 kW -1) 5) -1) 5)
3.2 l AXZ 184 kW -1) 5) -1) 5)
3.6 l BLV 206 kW -1) 5) -1) 5)
Vehicles with diesel en‐ Renewing left side light bulb - M1- Renewing right side light bulb - M3-
gine
Dis‐ En‐ Engine
place‐ gine
ment code
1.9 l BKC 77 kW -2) 6) -2) 6)
BLS 77 kW -2) 6) -2) 6)
2.0 l BMA 100 kW -2) 6) -2) 6)
BKP 103 kW -2) 6) -2) 6)
1. Headlight 197
gine
Dis‐ En‐ Engine
place‐ gine
ment code
BMP 103 kW -2) 6) -2) 6)
BMR 125 kW -2) 6) -2) 6)
2.5 l BKX 132 kW -2) 6) -2) 6)
Note
♦ The illustrations show renewal of the side light bulb for the right
light.
♦ Renewal of the left side light bulb - M1- and the right side light
bulb - M3- is analogue.
– Pull bulb holder -1- with side light bulb out of reflector as far
as wiring allows.

– Pull side light bulb -2- in direction of -arrow- out of bulb holder
-1-.
Installing:
Note

light.

1.5 Renewing headlight bulbs, headlight

manufacturer Valeo
1.5.1 Renewing headlight dipped beam bulb
Note
The left headlight dipped beam bulb - M29- and the right headlight
dipped beam bulb - M31- can be checked by the final control di‐
agnosis for the onboard supply control unit - J519- .
Removing:
Note

♦ It may be necessary to remove adjacent components at the
respective headlight when replacing the headlight dipped
beam bulb.
♦ The components to be removed (engine-specific) for replace‐
ment of headlight dipped beam bulb are indicated in the fol‐
lowing tables.
Dis‐ En‐ Engine
place‐ gine
ment code
1.6 l BSE 75 kW -1) 7) -1) 7)
BSF 75 kW -1) 7) -1) 7)
1. Headlight 199
Dis‐ En‐ Engine
place‐ gine
ment code
BLF 85 kW -1) 7) -1) 7)
2.0 l BLR 110 kW -1) 7) -1) 7)
BLX 110 kW -1) 7) -1) 7)
BVY 110 kW -1) 7) -1) 7)
AXX 147 kW -1) 7) -1) 7)
BPY 147 kW -1) 7) -1) 7)
3.2 l AXZ 184 kW -1) 7) -1) 7)
3.6 l BLV 206 kW -1) 7) -1) 7)
7) No additional work required
Vehicles with diesel en‐ Renewing left headlight dipped beam Renewing right headlight dipped beam
Dis‐ En‐ Engine
place‐ gine
ment code
1.9 l BKC 77 kW -2) 8) -2) 8)
BLS 77 kW -2) 8) -2) 8)
2.0 l BMA 100 kW -2) 8) -2) 8)
BKP 103 kW -2) 8) -2) 8)
BMP 103 kW -2) 8) -2) 8)
BMR 125 kW -2) 8) -2) 8)
2.5 l BKX 132 kW -2) 8) -2) 8)
8) No additional work required
Note
♦ The following figures show renewal of the dipped beam bulb

for the right headlight.
♦ Renewal of the left headlight dipped beam bulb - M29- and the
right headlight dipped beam bulb - M31- is analogue.

Note
♦ Headlight dipped beam bulb -2- is clipped into reflector -1-.

♦ The connector -3- is not pulled off initially when removing
headlight dipped beam bulb -2-.
– Push the connector and therefore also the bulb holder in di‐
rection of -arrow- until the bulb is detectably loosened.
– Pull headlight dipped beam bulb -3- on connector out from re‐
flector.
– Guide headlight dipped beam bulb along with connected con‐
nector out of headlight housing.
– Pull headlight dipped beam bulb -2- out of connector -1-.

Installing:
Note

light.

– Guide headlight dipped beam bulb into headlight housing.
– Push headlight dipped beam bulb, in installation position as

shown, into reflector.
Note
The headlight dipped beam bulb must audibly engage.
– Reconnect connector -1- to headlight dipped beam bulb -2-.

1. Headlight 201
1.5.2 Renewing headlight main beam bulb
Note
The left headlight main beam bulb - M30- and the right headlight
main beam bulb - M32- can be checked by the final control diag‐
nosis for the onboard supply control unit - J519- .
Removing:
Note

♦ To renew the headlight main beam bulb, it may be necessary
to remove components adjacent to the respective headlight.
placement of the headlight main beam bulb are indicated in
the following tables.
Dis‐ En‐ Engine
place‐ gine
ment code
1.6 l BSE 75 kW -1) 9) -1) 9)
BSF 75 kW -1) 9) -1) 9)
BLF 85 kW -1) 9) -1) 9)
2.0 l BLR 110 kW -1) 9) -1) 9)
BLX 110 kW -1) 9) -1) 9)
BVY 110 kW -1) 9) -1) 9)
AXX 147 kW -1) 9) -1) 9)
BPY 147 kW -1) 9) -1) 9)
3.2 l AXZ 184 kW -1) 9) -1) 9)
3.6 l BLV 206 kW -1) 9) -1) 9)
Dis‐ En‐ Engine
place‐ gine
ment code
1.9 l BKC 77 kW -2) 10) -2) 10)
BLS 77 kW -2) 10) -2) 10)
2.0 l BMA 100 kW -2) 10) -2) 10)
BKP 103 kW -2) 10) -2) 10)

Dis‐ En‐ Engine
place‐ gine
ment code
BMP 103 kW -2) 10) -2) 10)
BMR 125 kW -2) 10) -2) 10)
2.5 l BKX 132 kW -2) 10) -2) 10)
Note
♦ The following figures show renewal of the main beam bulb for
♦ Renewal of the left headlight main beam bulb - M30- and the
right headlight main beam bulb - M32- is analogue.
Note
♦ Headlight main beam bulb -2- is clipped into reflector -1-.

♦ The connector -3- is not pulled off initially when removing
headlight main beam bulb -2-.
– Push the connector and therefore also the bulb holder in di‐
rection of -arrow- until the bulb is detectably loosened.
– Pull headlight main beam bulb -3- on connector out of reflector.
– Guide headlight main beam bulb along with connected con‐
nector out of headlight housing.
1. Headlight 203
– Pull headlight main beam bulb -2- out of connector -1-.

Installing:
Note

light.

– Guide headlight main beam bulb into headlight housing.
– Push headlight main beam bulb, in installation position as

shown, into reflector.
Note
Headlight main beam bulb must engage audibly.
– Reconnect connector -2- to headlight main beam bulb -1-.

Note
The left side light bulb - M1- and the right side light bulb - M3- can
be checked by the final control diagnosis for the onboard supply
Removing:

Note

♦ To renew side light bulb, it may be necessary to remove com‐
ponents adjacent to the respective light.
placement of the side light bulb are indicated in the following
tables.
Vehicles with petrol en‐ Renewing left side light bulb - M1- Renewing right side light bulb - M3-
gine
Dis‐ En‐ Engine
place‐ gine
ment code
1.6 l BSE 75 kW -1) 11) -1) 11)
BSF 75 kW -1) 11) -1) 11)
BLF 85 kW -1) 11) -1) 11)
2.0 l BLR 110 kW -1) 11) -1) 11)
BLX 110 kW -1) 11) -1) 11)
BVY 110 kW -1) 11) -1) 11)
AXX 147 kW -1) 11) -1) 11)
BPY 147 kW -1) 11) -1) 11)
3.2 l AXZ 184 kW -1) 11) -1) 11)
3.6 l BLV 206 kW -1) 11) -1) 11)
gine
Dis‐ En‐ Engine
place‐ gine
ment code
1.9 l BKC 77 kW -2) 12) -2) 12)
BLS 77 kW -2) 12) -2) 12)
2.0 l BMA 100 kW -2) 12) -2) 12)
BKP 103 kW -2) 12) -2) 12)
BMP 103 kW -2) 12) -2) 12)
BMR 125 kW -2) 12) -2) 12)
2.5 l BKX 132 kW -2) 12) -2) 12)
1. Headlight 205
Note
♦ The following figures show renewal of the side light bulb for
the right light.
– Pull bulb holder -1- with side light bulb out of reflector as far
as wiring allows.
-1-.
Installing:
Note

light.


1.6 Removing and installing headlight range

control motor (headlight manufacturer
Hella)
Note
♦ The following illustrations show replacement of the headlight

range control motor on the right headlight.
♦ Renewal of the left headlight range control motor and right
headlight range control motor is analogue.
Removing:
– Remove headlight ⇒ page 188 .
– Turn headlight range control motor -1- in -direction of arrow-

and take it out.
– Pull connector -2- off headlight range control motor -1-.

Installing:
1. Headlight 207
– Carefully insert ball head of headlight range control motor -1-

in ball head guide -arrow- whilst pulling the reflector to the rear.
– Now insert the control motor into the mounting and turn it
clockwise through 30° until it engages.
Note
When installing cover cap, ensure that it seats properly. The in‐
gress of water will lead to permanent damage to the headlight.

control motor (headlight manufacturer
Valeo)
Note
♦ The following diagrams show renewal of the headlight range

control motor for the left headlight.
♦ The headlight range control motor for the right headlight is re‐
newed in the same manner.
Removing:
– Unscrew securing bolt -2- and remove housing -1- complete.
– Pull cog -1- upwards and out of the installation opening.
Note
Ensure that the small O-ring is not lost when removing the gear
wheel.


– Release headlight range control motor -1- by turning it in
-direction of arrow B-.
– Carefully press ball head of headlight range control motor
-arrow A- to rear and out of its guide.
– Remove headlight range control motor -1- upwards out of its
mounting.
Installing:
– Carefully guide headlight range control motor -1- (in its re‐
leased position) fully into its mounting.
– Lock headlight range control motor -1- by turning it onto stop

in -direction of arrow B-.
– Firstly, carefully press ball head of headlight range control
motor -arrow A- to rear.
– Then carefully pull ball head of control motor in

-direction of arrow- and into the mounting -1-.
Note
Pull the reflector slightly to the rear to ease the guidance of the
ball head into the mounting.
– Reconnect connector -2- to headlight range control motor.
1. Headlight 209
– Insert cog -1- into its installation opening.
– Install housing -1- and secure with screw -2-, then fit cap -3-.
Note
When installing cover cap, ensure that it seats properly. The in‐
gress of water will lead to permanent damage to the headlight.

1.8 Repairing headlight retaining tabs

If one or more headlight retaining tabs are damaged or broken
off, they can be renewed by installing the repair kit. There is no
need to renew the entire headlight.
1- Upper, outer retaining tab
2- Upper, inner retaining tab
3- Side retaining tab
4- Lower retaining tab
Note
♦ Check that there is no further damage to the headlight that

would make installation of the repair kit unnecessary.
♦ Two different repair kits are available for the left and right
headlight ⇒ ETKA (electronic parts catalogue) .
♦ The same repair kits are available for both manufacturers
(Hella and Valeo).
♦ Each repair kit contains the upper, side and lower headlight
retaining tab, four securing bolts and two banjo bolts.
♦ The following figures show renewal of the retaining tabs on the
right headlight.
♦ Renewal of the retaining tabs on the left headlight and renewal
of the retaining tabs on the right headlight are carried out in
the same way.
– Repairing upper, outer retaining tab ⇒ page 211 .

– Repairing upper, inner retaining tab ⇒ page 212 .
– Repairing side retaining tab ⇒ page 213 .
– Repairing lower retaining tab ⇒ page 214 .
1.8.1 Repairing upper, outer retaining tab

Note

1. Headlight 211
– Remove headlight retaining tab residues -1- as shown.
– Form-fit new retaining tab -2- into support -3- on headlight and
tighten securing bolt -1- for tab.
– Install headlight ⇒ page 189 .
Note

installation.

1.8.2 Repairing upper, inner retaining tab

Note


– Remove headlight retaining tab residues as shown.

Note

installation.

1.8.3 Repairing side retaining tab

Note


1. Headlight 213
– Screw banjo bolt -1- into retaining tab -2-.

Note

installation.

1.8.4 Repairing lower retaining tab

Note


– Form-fit new retaining tab -12- into support -3- on headlight

and tighten securing bolt -1- for tab.

– Screw banjo bolt -2- into retaining tab -1-.

Note

installation.

1.9 Converting headlights to drive on the left

or the right (manufactured by Hella)
Caution
♦ Danger of damaging / destroying plastic lens.

♦ The plastic lens of the headlight could be destroyed during
cleaning if an incorrect cleaning solution is used.
♦ Only use cleansers based on alcohol or an alcohol/water
mixture (for example a cloth soaked with isopropyl alco‐
hol) to clean the plastic lens.
Note
♦ To avoid dazzling oncoming traffic with asymmetrical lights,

both headlights should be converted to the direction of traffic
(driving on the left or right) relevant to the country in which the
vehicle is being driven.
♦ The corresponding headlight conversion set consists of two
sections of film.
♦ Conversion of the main headlights is not designed as a per‐
manent conversion for other countries. It is only suitable as a
“tourist solution” for a short stay abroad.
♦ Both headlights of a vehicle must always be converted.
♦ The details “right” and “left” on the masking film always refer
to the direction of travel when looking forwards from inside the
vehicle.
1.9.1 Converting headlights designed for driv‐

ing on the right to driving on the left
Note
♦ The headlight conversion set comprises two pieces of film.

♦ Please note the different part numbers for the headlight con‐
version sets from right to left-hand traffic and from left to right-
hand traffic.
♦ Clean headlight lens before converting. Remove residual ad‐
hesive from lens after pulling off application film ⇒ page 215 .
1. Headlight 215
– Turn light switch to position “0”.

Left headlight:
– Remove the protective backing on application film -D- in areas
-C- only.
– Align application film -D- with left radius to line -A- on the lens
of the headlight.
– At the same time, align application film -D- with right radius to
line -B- on the lens of the headlight.
– Push down in areas -C- on the lens of the headlight.
– Carefully pull application film -D- off the lens of the headlight
again.
– The masking film -C- remains on the headlight lens.
Right headlight:
– Remove protective film on back of assembly film -D- in area

-C- only.
of the headlight.
– Push down in area -C- on the headlight lens.
again.
Note
♦ Remove any remaining adhesive using only alcohol-based or

alcohol and water-based cleaning fluid. For example a cloth
soaked with isopropyl alcohol ⇒ page 215 .
♦ Customers should be informed of how to remove residual ad‐
hesive after detaching the masking section.
Functional check of masking film:

– Check the function of the masking film using headlight align‐
ment unit - VAS 5046- , for example.
– The upper light/dark zone is supposed to touch the setting line
and run across the whole width of the measuring screen hor‐
izontally.


ing on the left to driving on the right
Note

hand traffic.

Left headlight:
-C- only.
of the headlight.
again.
Right headlight:

-C- only.
of the headlight.
again.
Note

1. Headlight 217

izontally.
1.10 Converting headlights to drive on the left

or the right (manufactured by Valeo)
Caution

Note
♦ To avoid dazzling oncoming traffic with asymmetrical lights,

both headlights should be converted to the direction of traffic
(driving on the left or right) relevant to the country in which the
vehicle is being driven.
sections of film.
vehicle.

Note

hand traffic.


Left headlight:
– Remove protective backing on application film -C- in area
-D- only.
– Align application film -C- with its radius to line -A- on the lens
of the headlight.
– At the same time, align application film -C- edge -B- with the
third line on the lens of the headlight.
– Push down firmly in area -D- on the lens of the headlight.
– Carefully pull application film -C- off the lens of the headlight
again
– The masking film -D- remains on the headlight lens.
Right headlight:

-D- only.
– Align application film -C- with its radius to line -B- on the lens
of the headlight.
– At the same time, align application film -C- edge -A- with the
again
Note


izontally.
1. Headlight 219

Note

hand traffic.

Left headlight:
-D- only.
– Align application film -C- with its radius to line -A- on the lens
of the headlight.
– At the same time, align application film -C- edge -B- with the
again
Right headlight:

-D- only.
– Align application film -C- with its radius to line -B- on the lens
of the headlight.
– At the same time, align application film -C- edge -A- with the
again
Note



izontally.
1.11 Adjusting headlights

Adjusting headlights ⇒ Maintenance ; Booklet 21.1
1. Headlight 221
2 Headlights with gas discharge bulb

and cornering light
Note
♦ Before working on headlights with gas discharge bulbs and

cornering lights, always switch off the headlights and move the
ignition key or start button to position 0 (pre-detent).
♦ The automatic headlight range control and cornering lights on
headlights with gas discharge bulbs is equipped with self-di‐
agnosis.
♦ When dealing with complaints, it is absolutely essential that
the function and operation of the lighting system are first un‐
derstood.
Cornering Light System
Passat 2006
tions
The main headlights with gas discharge bulbs and cornering lights
(AFS = Adaptive Front Lighting System) have a “bi-xenon” func‐
tion.
With conventional “xenon” headlights, the gas discharge bulbs
only generate the dipped beam. The “bi-xenon” features makes
it possible to generate both the dipped beam and the main beam
with “one” gas discharge bulb. To achieve this, an electrome‐
chanical adjuster ( left dip beam screen motor - V294- or right dip
beam screen motor - V295- ) uncovers the screened area of the
dipped beam on actuation of the main beam function, thus pro‐
ducing main beam light distribution.
This means that with “bi-xenon” headlights the main beam is al‐
ways automatically adjusted together with the dipped beam.
The main headlights with gas discharge bulbs and cornering lights
do not have an “additional main beam”.
The cornering light system consists of the following functions:
♦ Swivelling main and dipped beams (dynamic cornering light):
at vehicle speeds above 10 kmh with steering input.
♦ Cornering light bulb (static cornering light): when turning into
tight bends (bend radius < 500 m) or when cornering at vehicle
speeds below 50 kmh.
The automatic headlight range control, the cornering lights and
onboard supply control systems feature self-diagnosis to facilitate
fault finding for main headlights with gas discharge bulbs.


Note
The “bulb failure” warning lamp lights up in the dash panel when
the headlight range control or the AFS (adaptive front lighting
system) malfunctions ⇒ Item 21 (page 148) .
2.1 Assembly overview - headlight with gas

discharge bulb and cornering lights
Note
After any measures which could affect the headlight setting, the
headlights must be checked and if necessary adjusted ⇒ Main‐
tenance ; Booklet 21.1 .
1 - Cover cap
2 - Left cornering light bulb -
L148- or right cornering light
bulb - L149-
❑ Bulb H7 12 V, 55 W
3 - Left side light bulb - M1- or
right side light bulb - M3-
❑ Bulb 12 V, BLUE W 5 W
4 - Securing bolts
❑ 2 Nm
5 - Headlight
⇒ page 188
❑ Correcting installation
position of headlight
⇒ page 190
❑ Converting headlights
to drive on the left or the
right ⇒ page 241
❑ Perform basic setting
⇒ Maintenance ; Book‐
let 21.1 .
6 - Securing bolts
❑ 8 Nm
7 - Adjustment bushes
❑ Correcting installation
position of headlight
⇒ page 190
2. Headlights with gas discharge bulb and cornering light 223

8 - Retaining ring
9 - Securing bolts
10 - Control unit for left gas discharge bulb - J343- or control unit for right gas discharge bulb - J344-
11 - Wiring for gas discharge bulb
12 - Left gas discharge bulb - L13- or right gas discharge bulb - L14- (“bi-xenon”)
❑ Type D1S, 35 W
13 - Left headlight range control motor - V48- or right headlight range control motor - V49-
14 - Cap
15 - Seal
16 - Output module for left headlight - J667- or output module for right headlight - J668-
Note
The cornering light and headlight

range control unit - J745- must be
recoded ⇒ page 239 if a new power
output module for headlight is instal‐
led. Then subsequently perform the
basic setting of the headlights
⇒ Maintenance ; Booklet 21.1
17 - Securing bolts
18 - Body aperture
19 - Cornering light and headlight range control unit - J745-
❑ Coding ⇒ page 239
❑ Final control diagnosis ⇒ page 240 .
❑ Adaption ⇒ page 240
Note
If the cornering light and headlight

range control unit - J745- has to be
coded, basic setting of the head‐
lights must be performed after cod‐
ing ⇒ Maintenance ; Booklet 21.1 .

– Removing and installing headlights ⇒ page 188 .
2.3 Adjusting headlight installation position

– Adjusting headlight installation position ⇒ page 190

2.4 Renewing bulbs of headlight with gas

discharging bulb and cornering light
2.4.1 Renewing gas discharge bulb ► 11.2007
Note
♦ Left gas discharge bulb - L13- and right gas discharge bulb -
L14- can be checked by the final control diagnosis for the
onboard supply control unit - J519- ⇒ page 424 .
♦ The illustrations show renewal of the gas discharge bulb for
♦ Renewal of the left gas discharge bulb - L13- and the right gas
discharge bulb - L14- is analogous.
Removing:
– Push bulb retaining spring -1- in direction of -arrow-.
– Pull cap -1- with power output module for headlight -2- off
headlight in direction of -arrow-, as far as cable length allows.
Note
The power output module for headlight -2- must not be unscrewed
from the cap -1-.

– Release connectors -arrows- and pull the connectors off.
WARNING
♦ Within the glass bulb of a gas discharge bulb, pressure

can range from between 7 bar (cold) and 100 bar (hot).
Temperatures can reach up to 700 degrees Celsius on the
glass bulb.
♦ Should the glass bulb explode, there is a risk of injury from
burning.
♦ Always wear eye protection and gloves when removing
and installing gas discharge bulbs!
– Pull connector -1- off gas discharge bulb -2-.

– Release retaining clip -1- and swing it aside

– Carefully pull gas discharge bulb -2- out of holder.
Installing:
Note
♦ Do not touch glass bulb when fitting gas discharge bulb. Fin‐
gers leave traces of grease on the glass bulb, which evaporate
when the bulb is switched on and cause the glass bulb to cloud
over.
♦ Ensure that the glass bulb is not stressed mechanically. The
glass bulb is extremely sensitive and is also under a high in‐
ternal pressure.
♦ Avoid looking directly into the collimated beam as the UV rays
from the gas discharge bulb are about 2.5 times greater than
normal halogen bulbs.
♦ When installing bracket together with power output module for
headlight, ensure that seal is seated correctly. The ingress of
water will lead to permanent damage to the headlight.
♦ If a headlight with automatic range control is removed, the ba‐
sic setting of the headlight should always be checked when
reinstalling ⇒ Maintenance ; Booklet 21.1 .
– Insert new gas discharge bulb so that locking lugs are posi‐
tioned in recesses on reflector.
2.4.2 Renewing gas discharge bulb 11.2007

►
Note
♦ Left gas discharge bulb - L13- and right gas discharge bulb -
L14- can be checked by the final control diagnosis for the
♦ The illustrations show renewal of the gas discharge bulb for
♦ Renewal of the left gas discharge bulb - L13- and the right gas
discharge bulb - L14- is analogous.

Removing:
WARNING
♦ Within the glass bulb of a gas discharge bulb, pressure

can range from between 7 bar (cold) and 100 bar (hot).
Temperatures can reach up to 700 degrees Celsius on the
glass bulb.
♦ Should the glass bulb explode, there is a risk of injury from
burning.
♦ Always wear eye protection and gloves when removing
and installing gas discharge bulbs!

Note
from the cap -1-.

– Release gas discharge bulb by turning catch -1-.
– Carefully pull gas discharge bulb -B- out of holder -C-.

– Pull connector -A- off gas discharge bulb -B-.
Installing:
– Insert new gas discharge bulb so that locking lug on reflector

-A- is positioned in recess -B- of gas discharge bulb.
– Carefully press gas discharge bulb -B- into locking lug -C- until
bulb can be felt to engage.

– Lock gas discharge bulb by turning catch -1-.

Continue installation in the reverse order of removal, noting the
following:
Note
♦ When installing the housing cover with the gas discharge bulb
control unit, ensure that the seal is seated correctly. The in‐
gress of water will destroy the headlight.

Note
♦ Left side light bulb - M1- and right side light bulb - M3- can be
checked from onboard supply control unit - J519- by means of
the final control diagnosis function ⇒ page 424 .
♦ The following figures show renewal of the side light bulb for
the right light.
Removing:
Note

– Push retaining springs -1- and -2- to side in

– Remove cover cap -3- from headlight.

– Pull grip -1- with side light bulb out of reflector as far as wiring
allows.
-1-.
Installing:
Note
♦ When installing cover cap, ensure seal is seated correctly. The

light.

2.4.4 Renewing cornering light bulb (static

cornering light)
Note
♦ Left cornering light bulb - L148- and right cornering light bulb
- L149- can be checked by the final control diagnosis for the
cornering light and headlight range control unit - J745-
⇒ page 240 .
♦ The following figures show renewal of the cornering light bulb
for the right light.
♦ Renewal of the left cornering light bulb - L148- and the right
cornering light bulb - L149- is analogue.
Removing:

Note

– Push retaining springs -1- and -2- to side in

– Remove cover cap -3- from headlight.
Note
♦ Cornering light bulb -1- is clipped into reflector -2-.

♦ Initially, connector -3- is not disconnected on removing the
cornering light bulb.
– Push connector with bulb holder in direction of -arrow- until the

bulb is detectably loosened.
– Pull cornering light bulb out of reflector by gripping on con‐
nector -3-.
– Guide cornering light bulb along with connected connector out
of headlight housing.
– Pull cornering light bulb -2- out of connector -1-.

Installing:
– Guide cornering light bulb into headlight housing.

– Push cornering light bulb -1- into reflector in installation posi‐

tion as shown.
Note
♦ Cornering light bulb must engage audibly.

light.
– Reconnect connector for cornering light bulb.

2.5 Headlight range control motor
2.5.1 Removing and installing headlight range

control motor
Note
♦ The following illustrations show replacement of the headlight

range control motor on the right headlight.
♦ Renewal of the left headlight range control motor and right
headlight range control motor is analogue.
Removing:

Note
from the cap -1-.
– Carefully prise adjustment screw -1- out of headlight housing

in -direction of arrow-.
– Pull connector -2- off headlight range control servomotor -1-.

– Turn headlight range control motor -1- in -direction of arrow-
and take it out.
Installing:

– Carefully insert ball head of headlight range control motor -1-

in ball head guide -2- whilst pulling eflector to rear.
– Now insert the control motor into the mounting and turn it
clockwise through 30° until it engages.
Note

light.
2.5.2 Checking headlight range control motor

Left headlight range control motor - V48- and right headlight range
control motor - V49- can be checked by the final control diagnosis
for the cornering light and headlight range control unit - J745-
⇒ page 240 .
2.6 Dynamic cornering light control motor

The left dynamic cornering light control motor - V318- or right dy‐
namic cornering light control motor - V319- are located inside the
respective headlight and must not be dismantled.
In the event of damage, the headlight must be renewed
⇒ page 188 .
2.6.1 Checking dynamic cornering light con‐

trol motor
Left dynamic cornering light control motor - V318- and right dy‐
namic cornering light control motor - V319- can be checked by
the final control diagnosis for the cornering light and headlight
range control unit - J745- ⇒ page 240 .
2.7 Swivel module position sensor

The left swivel module position sensor - G474- or right swivel
module position sensor - G475- are located inside the respective
headlight and can neither be individually renewed nor adjusted.
⇒ page 188 .
2.8 Dipped beam screen

With conventional “xenon” headlights, the gas discharge bulbs
only generate the dipped beam. The “bi-xenon” features makes
it possible to generate both the dipped beam and the main beam
with “one” gas discharge bulb. To achieve this, an electrome‐
chanical adjuster ( left dip beam screen motor - V294- or right dip
beam screen motor - V295- ) uncovers the screened area of the
dipped beam on actuation of the main beam function, thus pro‐
ducing main beam light distribution.
2.8.1 Removing and installing dipped beam

screen
The left dip beam screen motor - V294- or right dip beam screen
motor - V295- are located inside the respective headlight and can
neither be individually replaced nor adjusted.


⇒ page 188 .
2.8.2 Checking dipped beam screen motor

Left dip beam screen motor - V294- and right dip beam screen
motor - V295- can be checked by the final control diagnosis for
the onboard supply control unit - J519- ⇒ page 424 .
2.9 Power output module for headlight
2.9.1 Removing and installing power output

module for headlight
Note
♦ The diagrams show renewal of the power output module for

♦ Replacement of the power output module for left headlight -
J667- and the power output module for right headlight - J668-
is analogue.
Note
♦ A mixed installation between old type headlight housing, to

parts index 3C0 941 753 K or 754 K, and output module 7L6
941 329 A is not permissible.
♦ A mixed installation between new type headlight housing, from
941 329 or 330 is not permissible.
♦ A mixed installation can cause a faulty diagnosis when fault
finding.
Removing:
– Unscrew securing screws -arrows- from power output module
for headlight -1-.


– Remove power output module for headlight from headlight.
Installing:
Note
♦ Ensure when installing the covers and the power output mod‐
ules for headlight that the seals are seated correctly. The
light.
♦ The cornering light and headlight range control unit - J745-
must be recoded ⇒ page 239 if a new power output module
for headlight is installed. Then subsequently perform the basic
setting of the headlights ⇒ Maintenance ; Booklet 21.1

2.9.2 Coding power output module for head‐

light
Note
♦ A mixed installation between old type headlight housing, to

941 329 A is not permissible.
♦ A mixed installation between new type headlight housing, from
941 329 or 330 is not permissible.
♦ A mixed installation can cause a faulty diagnosis when fault
finding.
Note
The cornering light and headlight range control unit - J745- must
be recoded if a new power output module for headlight is installed.
Then subsequently perform the basic setting of the headlights.
– Coding cornering light and headlight range control unit - J745-

⇒ page 239 .
– Carry out basic setting of headlights ⇒ Maintenance ; Booklet
21.1 .

2.10 Removing and installing gas discharge

bulb control unit
Note
♦ The left gas discharge bulb control unit - J343- or right gas
discharge bulb control unit - J344- is not capable of self-diag‐
nosis.
♦ The diagrams show renewal of the gas discharge light control
unit for the right headlight.
♦ The renewal of the left gas discharge bulb control unit - J343-
and the right gas discharge bulb control unit - J344- are
analogue.
Removing:
– Remove securing screws -arrows- and pull gas discharge light
control unit -1- off headlight as far as wiring allows.
– Release locking lug -arrow A- of connector -1- and pull con‐

nector -1- off.
– Release locking pin -3- of connector -2- in direction of
-arrow B- and disconnect connector -2-.
Installing:
Caution
When installing gas discharge light control unit, ensure that

seals are properly seated. The ingress of water will lead to
permanent damage to the headlight.


2.11 Cornering light and headlight range con‐

trol unit - J745-
2.11.1 Removing and installing cornering light

and headlight range control unit - J745-
– Remove glove compartment ⇒ General body repairs, interior;
Rep. gr. 68 ; Compartments, covers and trims; Removing and
installing glove compartment .
– Release connector in direction of -arrow- and disconnect con‐
nector -1- from cornering light and headlight range control unit
- J745- -2-.
– Remove securing bolts -arrows- and remove cornering light

and headlight range control unit - J745- -1-.
Installing:
Note
The new cornering light and headlight range control unit must be
coded once it is installed ⇒ page 239 . Then subsequently per‐
form the basic setting of the headlights ⇒ Maintenance ; Booklet
21.1 .

2.11.2 Coding cornering light and headlight

range control unit - J745-
♦ Body
♦ Automatic headlight range control, cornering lights
♦ Headlight range control functions
♦ Coding control unit for AFS light control

Note
If the cornering light and headlight range control unit - J745- has
to be coded, basic setting of the headlights must be performed
after coding ⇒ Maintenance ; Booklet 21.1 .
2.11.3 Cornering light and headlight range con‐

trol unit - J745- final control diagnosis
The following components and functions can be checked by the
final control diagnosis for the convenience system central control
unit - J393- :
♦ Left headlight range control motor - V48- or right headlight
♦ Left dynamic cornering light control motor - V318- or right dy‐
namic cornering light control motor - V319-
♦ Left cornering light bulb - L148- or right cornering light bulb -
L149-
♦ Headlight range control lamp in dash panel
♦ AFS (adaptive front lighting system) lamp in dash panel
Note
The “bulb failure” warning lamp lights-up in the dash panel when
the headlight range control or the AFS (adaptive front lighting
system) malfunctions ⇒ Item 21 (page 148) .

♦ Body
♦ Automatic headlight range control, cornering lights
♦ Headlight range control functions
♦ AFS final control diagnosis
2.11.4 Adapting cornering light and headlight

range control unit - J745-
The function “Adapting cornering light and headlight range control
unit” could not be included before date of publication.
2.12 Vehicle level sender

There is a vehicle level sender located on the front axle ( front left
vehicle level sender - G78- ) and on the rear axle ( rear left vehicle
level sender - G76- ).
The vehicle level senders form part of the headlight range control
system.
The vehicle level senders transmit the longitudinal inclination an‐
gle in the form of a PWM signal (pulse width modulation signal)

to the control unit for cornering light and headlight range control
- J745- .
For generation of this PWM signal, the rear left vehicle level send‐
er - G76- is supplied with power via two positive wires and an earth
wire. The front left vehicle level sender - G78- is supplied with
power via one positive wire and two earth wires.
Removing and installing vehicle level senders :
Removing and installing front left vehicle level sender - G78- ⇒
Running gear, axles, steering; Rep. gr. 40 ; Subframe, anti-roll
bar, suspension links; Assembly overview - subframe, anti-roll
bar, suspension links .
Removing and installing rear left vehicle level sender - G76- ⇒
Running gear, axles, steering; Rep. gr. 42 ; Assembly overview
- subframe, transverse links, track rods; Vehicle level sender for
vehicles with automatic headlight range control .
Note
If the vehicle level senders are renewed, basic setting of the

headlights must be performed ⇒ Maintenance ; Booklet 21.1 .
2.13 Repairing headlight retaining tabs

If one or more headlight retaining tabs are damaged or broken
off, they can be renewed by installing the repair kit. There is no
need to renew the entire headlight.
Repairing headlight retaining tabs for headlights with gas dis‐
charge bulbs and cornering lights is carried out in the same
manner as for conventional headlights ⇒ page 211 .
2.14 Converting headlights for use when driv‐

ing on the left or right
Caution


Note
♦ To avoid dazzling oncoming traffic with the asymmetrical

lights, both headlights should be converted relevant to the
country (driving on the left or right) in which the vehicle is being
driven.
sections of film.
vehicle.

Note

hand traffic.
♦

Left headlight:
-D- only.
– Align application film -C- edge -A- with the third line on the lens
of the headlight.
– At the same time, align application film -C- with its radius to
again
Right headlight:


-D- only.
– Align application film -C- edge -B- with the third line on the lens
of the headlight.
line -A- on the lens of the headlight.
again
Note


izontally.

Note

hand traffic.

Left headlight:
-D- only.
– Align application film -C- edge -A- with the third line on the lens
of the headlight.
again
Right headlight:

-D- only.
– Align application film -C- edge -B- with the third line on the lens
of the headlight.
line -A- on the lens of the headlight.
again
Note


izontally.
2.15 Adjusting headlights

– Adjusting headlights with gas discharge bulbs ⇒ Mainte‐
nance ; Booklet 21.1 .

3 Fog lights
Note
The function of the fog lights can be tested using the final control
diagnosis of the onboard supply control unit - J519- .

3.1 Assembly overview - fog lights
1 - Front bumper
2 - Bleeder hose
3 - Left fog light bulb - L22- or
right fog light bulb - L23-
❑ Bulb H11 12 V, 55 W
⇒ page 246
4 - Fog light housing
⇒ page 246
5 - Cover
6 - Securing bolts
❑ Specified torque
⇒ page 335
3. Fog lights 245

3.2 Removing and installing fog light
Note
The illustrations show removal and installation of the front left fog
light. The removal of the front right fog light is basically a mirror
image.
Removing:
– Remove securing bolt -1- and unclip top -arrow - of trim -2-
from bumper cover.

– Pull fog light housing out of bumper carefully taking connected
wiring length into consideration.
– Release and disconnect connector -arrow-.

Installing:
– Tighten securing bolts to specified torques ⇒ page 335 .
– After completion of installation, check function of fog light.
– Check fog light setting and adjust if necessary ⇒ Maintenance ;
Booklet 21.1 .
3.3 Removing and installing fog light bulb
Note
Illustration shows removal and installation on left fog light.

Removing:
– Remove fog light ⇒ page 246 .
– Turn bulb holder with fog light bulb -1- in direction of arrow and
remove from fog light housing.
The bulb for the fog light is permanently attached to the bulb
holder and cannot be renewed separately.
Fog light bulb : H11 12 V, 55 W
Installing:
– After completion of installation, check function of headlight.
– Check fog light setting ⇒ page 247 and adjust if necessary
⇒ page 247 .
3.4 Checking fog lights

The fog lights ( left fog light bulb - L22- and right fog light bulb -
L23- ) can be checked by the final control diagnosis for the
3.5 Adjusting fog lights

Adjusting fog lights ⇒ Maintenance ; Booklet 21.1 .
3. Fog lights 247

4 Front turn signals
Note
The function of the front turn signals can be tested using the final
control diagnosis of the onboard supply control unit - J519- .

4.1 Removing and installing front turn signal
Note
The illustrations show removal and installation of the front left turn
signal. The removal of the front right turn signal is basically a mir‐
ror image.
Removing:
Note

– Remove securing screw -1- and unclip cover -2- fastener

-arrow- from bumper cover.

– Remove securing bolt -arrow- from underside of turn signal.

– Pull turn signal -1- out of bumper cover, taking connected wir‐
ing length into consideration.
– Release and disconnect connector -1- and remove turn signal

-2- along with clipped on protective strip.
– Release the fasteners -arrows- of the clipped on protective

strip using a suitable screwdriver and remove the unclipped
protective strip -2- from the turn signal -1-.
Installing:
Note
Ensure all fasteners are correctly engaged when fitting the pro‐
tective strip on the turn signal housing.
4.2 Removing and installing turn signal bulb
Note
Illustration shows removal and installation on left turn signal.
Removing:
– Remove front turn signal ⇒ page 248 .
4. Front turn signals 249

– Turn bulb holder -1- in direction of -arrow- and remove from

turn signal housing -2-.
– Pull turn signal bulb out of bulb holder.
Turn signal bulb : 12 V 21 W
Installing:
Note
Do not touch bulb glass when fitting bulbs. Fingers leave traces
of grease on the glass, which evaporate when the bulb is switched
on and cause the glass to cloud over.
4.3 Checking front turn signal

The front turn signals ( front left turn signal bulb - M5- and front
right turn signal bulb - M7- ) can be checked by the final control
diagnosis for the onboard supply control unit - J519-
⇒ page 424 .

5 Bulb for mirror turn signal and entry

light in exterior mirror
Note
The function of the bulb for turn signal repeater and entry light in
exterior mirror can be checked by the final control diagnosis of
the driver door control unit - J386- or front passenger door control
unit - J387- .

tions
The driver door control unit - J386- or the front passenger door
control unit - J387- features self-diagnosis to facilitate fault find‐
ing.
Bulbs for mirror repeater turn signals (side repeater turn signal)
are integrated in the exterior mirror housings.
In addition, there is an entry light in each exterior mirror housing
which illuminates the entry area around the open driver or front
passenger door in the dark.
1 - Driver side turn signal repeater bulb - L131- or front passenger
side turn signal repeater bulb - L132-
2 - Driver side entry light in exterior mirror - W52- or front pas‐
senger side entry light in exterior mirror - W53-
5.1 Turn signal repeater bulb
5.1.1 Removing and installing turn signal re‐

peater bulb
The driver side turn signal repeater bulb - L131- or front passen‐
ger side turn signal repeater bulb - L132- is located in the housing
of the left or right exterior mirror.
Note
In the event of damage, the complete driver side turn signal re‐
peater bulb - L131- unit or the complete front passenger side turn
signal repeater bulb - L132- unit must be renewed.
Removing:
5. Bulb for mirror turn signal and entry light in exterior mirror 251
Note

– Remove driver side turn signal repeater bulb - L131- unit or

front passenger side turn signal repeater bulb - L132- unit ⇒
General body repairs, exterior; Rep. gr. 66 ; Exterior mirror;
Removing and installing turn signal repeater .
Installing:
– Install driver side turn signal repeater bulb - L131- or front
passenger side turn signal repeater bulb - L132- ⇒ General
body repairs, exterior; Rep. gr. 66 ; Exterior mirror; Removing
and installing turn signal repeater .
5.1.2 Checking turn signal repeater bulb

The driver side exterior mirror turn signal bulb - L131- can be
checked by the final control diagnosis for the driver door control
unit - J386- ⇒ page 437 .
The front passenger side exterior mirror turn signal bulb - L132-
can be checked by the final control diagnosis for the driver door
control unit - J387- ⇒ page 438 .
5.2 Entry light in exterior mirror
5.2.1 Removing and installing entry light in ex‐

terior mirror
The driver side entry light in exterior mirror - W52- and the front
passenger side entry light in exterior mirror - W53- are installed
in the left/right exterior mirror housing respectively.
Note
♦ Removing and installing the entry lights does not involve dis‐
mantling the exterior mirror.
♦ The procedure for removal and installation of the bulb on the
driver and front passenger side is the same and is therefore
described for one side only.
Removing:
Note


– Fold exterior mirror -1- forwards in direction of arrow.
– Unclip entry light from exterior mirror in direction of arrow and

pull it out as far as wiring allows.
– Pull holder -2- in direction of arrow out of entry light housing

-1-.
Renewing bulb:
5. Bulb for mirror turn signal and entry light in exterior mirror 253
– Pull push-fit bulb -1- in the direction of the arrow out of bulb
holder -2-.
Push-fit bulb: 12 V, 6 W
Installing:
Note
Following installation, check operation of exterior mirrors.
5.2.2 Checking entry light in exterior mirror

The driver side entry light in exterior mirror - W52- can be checked
by the final control diagnosis for the driver door control unit - J386-
⇒ page 437 .
The front passenger side entry light in exterior mirror - W53- can
be checked by the final control diagnosis for the driver door con‐
trol unit - J387- ⇒ page 438 .

6 Tail lights
Note
The function of the tail lights can be tested using the final control
diagnosis of the onboard supply control unit - J519- .

The tail lights cannot be dismantled (except for the right reversing
light and the left rear fog light). The right reversing light and the
left rear fog light have bulbs which can be replaced. The other
lighting is produced by light emitting diodes (LEDs). Defective
light emitting diodes cannot be replaced.
Note
♦ LED failure in LED tail light cluster (not USA and Canada):
♦ The individual LEDs (light-emitting diodes) in the LED tail light
clusters (tail lights, brake lights, turn signals and reversing
lights) are comprised in groups of four LEDs and are supplied
with current in groups.
♦ The LED tail light clusters are designed in such a way that the
legal requirements of the ECE regulations (Economic Com‐
mission for Europe) are still met in the event that one LED
group per function (e.g. brake light) fails.
♦ If a further LED group per function fails, these requirements
are no longer met according to the legislator.
♦ Due to the failure of one LED group, this function's intact LEDs
are placed under increased strain; it must be anticipated that
further LED groups will soon fail.
♦ If more than four individual LEDs in an LED tail light cluster
function have failed, the entire LED tail light cluster must be
renewed (repair measure).
6.1 Tail light in side panel (saloon)
6.1.1 Assembly overview - tail light in side panel
6. Tail lights 255

1 - Studs on tail light in side

panel
2 - Securing nuts
⇒ page 335
3 - Tail light in side panel
⇒ page 256
4 - Connector for tail light in
side panel
6.1.2 Removing and installing tail light in side

panel
The tail light in the side panel cannot be dismantled again. It com‐
prises the following components:
♦ Left tail light bulb - M4- or right tail light bulb - M2-
♦ Left brake light bulb - M9- or right brake light bulb - M10-
♦ Rear left turn signal bulb - M6- or rear right turn signal bulb -
M8-

Removing:
Note
The illustrations show removal and installation for the left side.
The removal of the right side is basically a mirror image.

Note

– Unclip service cover -1- from side panel -2- in direction of ar‐
row.
– Release connector -2- by pulling lock button -3- in direction of

arrow and pull it off tail light.
– Remove securing nuts -1- and remove tail light to rear out of
side panel.
Installing:
6. Tail lights 257

Note
♦ Tail light connector -2- in side panel should be “heard” to en‐

gage when reconnecting.
♦ The connector is engaged correctly when the lock button -3-
is pressed down again.
6.1.3 Checking tail light in side panel

The tail light in the side panel ( left tail light bulb - M4- , right tail
light bulb - M2- , left brake light bulb - M9- , right brake light bulb
- M10- , rear left turn signal bulb - M6- , rear right turn signal bulb
- M8- ) can be checked by the final control diagnosis for the on‐
board control unit - J519- ⇒ page 424 .
6.2 Tail light in rear lid (saloon)
6.2.1 Assembly overview - tail light in rear lid

1 - Threaded studs on tail light

housing
2 - Securing nuts
⇒ page 335
rear lid
4 - Bulb carrier
⇒ page 260
5 - Rear left fog lamp bulb -
L46- or right reversing light
bulb - M17-
❑ 12 V, P 21 W
6 - Tail light housing
⇒ page 259
6.2.2 Removing and installing tail light in rear

lid
6. Tail lights 259

Note
Removing:
– Unclip service flap -1- in -direction of arrow- out of trim -2-.
– Release connector -1- and pull it off bulb holder -2-.

– Remove both securing nuts -3-.
– Remove tail light backwards out of rear lid.
Installing:
– When installing the tail light, tighten the upper nut first and then
the lower nut.
– Push connector into bulb holder until it can be heard to en‐
gage.
– When installation is complete, check gap/shut lines of tail light
to body.
6.2.3 Removing and installing tail light bulb

carrier in rear lid
Removing:

– Unclip service flap -1- in -direction of arrow- out of trim -2-.
– Turn bulb holder -1- in -direction of arrow- and remove it from

tail light housing.
Rear left fog light bulb - L46- 12 V, P 21 W
Right reversing light bulb - M17- 12 V, P 21 W
Installing:
following:
gage.
6.2.4 Checking tail light in rear lid

The tail lights in rear lid ( rear left fog light bulb - L46- and right
reversing light bulb - M17- ) can be checked by the final control
⇒ page 424 .
6.3 Tail light in side panel (Variant)
6.3.1 Assembly overview - tail light in side panel
6. Tail lights 261

1 - Adjust at double stud

2 - Connector on tail light in
side panel
3 - Spring-loaded locking lug
on tail light in side panel
4 - Pop rivet nut
❑ Mounting in body for
double stud.
5 - Double stud
❑ To align tail light in body.
6 - Tail light in side panel
⇒ page 262
7 - Securing nut for tail light
⇒ page 335
8 - Cover
6.3.2 Removing and installing tail light in side

panel
The tail light in the side panel cannot be dismantled again. It com‐
prises the following components:
♦ Left tail light bulb - M4- or right tail light bulb - M2-
♦ Left brake light bulb - M9- or right brake light bulb - M10-
♦ Rear left turn signal bulb - M6- or rear right turn signal bulb -
M8-

♦ Removal wedge - VAS 3409-
Removing:
Note
♦ When removing and installing components that are in view

(switches, covers, trim and so on), mask off areas in which
tools ( removal wedge - 3409- , screwdriver) are used to lever
out those components using commercially available tape.
♦ The illustrations show removal and installation for the right
side. The removal of the left side is basically a mirror image.

Note

– Open rear lid.
6. Tail lights 263

– Unclip cover -1- in -direction of arrow-, starting at edge of tail

light.
– Remove 14 mm securing nut -1- of tail light.
Note
The tail light in side panel is clipped to the body on the inner side
by two spring-loaded locking lugs. To unclip the locking lugs,
press tail light outwards at front.
– First press front part of tail light outwards -arrow A- to unclip

the locking lugs.
Note
Carefully assist the unclipping of the locking lugs along the front
edge of the tail light with a removal wedge - 3409- if necessary.
– Then pull the tail light -1- to rear -arrow B- out of opening in
the body, as far as the connected wiring allows.
– Release connector -2- by pulling on the locking button -3- and

disconnect the connector.
– Remove tail light -1- to rear off vehicle.
Installing:


Note
♦ Tail light connector -2- in side panel should be “heard” to en‐

gage when reconnecting.
♦ The connector is engaged correctly when the locking button
-3- is pressed down again.
♦ Ensure that both spring-loaded locking lugs audibly engage
when inserting the tail light.
– Tighten tail light securing nut to specified torque

⇒ page 335 .
– After installing the tail light, check the gap/shut line dimensions
to body and adjust as required at double stud
⇒ Item 5 (page 262) .
6.3.3 Checking tail light in side panel

The tail light in the side panel ( left tail light bulb - M4- , right tail
light bulb - M2- , left brake light bulb - M9- , right brake light bulb
- M10- , rear left turn signal bulb - M6- , rear right turn signal bulb
- M8- ) can be checked by the final control diagnosis for the on‐
board control unit - J519- ⇒ page 424 .
6.4 Tail light in rear lid (Variant)
6.4.1 Assembly overview - tail light in rear lid
6. Tail lights 265

1 - Studs on tail light housing in

rear lid
2 - Securing nuts
⇒ page 335
rear lid
4 - Bulb carrier
⇒ page 267
5 - Rear left fog lamp bulb -
L46- or right reversing light
bulb - M17-
❑ 12 V, P 21 W
6 - Tail light housing in rear lid
⇒ page 266
6.4.2 Removing and installing tail light in rear

lid

Note
Removing:
– Unclip service flap -1- out of trim in rear lid in direction of arrow.

– Remove both securing nuts -1-.
– Remove tail light backwards out of rear lid.
Installing:
– When installing the tail light, tighten the upper nut first and then
the lower nut.
– Push connector -2- into bulb holder -3- until it audibly engages.
– When installation is complete, check gap/shut lines of tail light
to body.
6.4.3 Removing and installing tail light bulb

carrier in rear lid
Removing:
6. Tail lights 267

– Unclip service flap -1- out of trim in rear lid in direction of arrow.
– Turn bulb holder -1- in direction of arrow and remove it from

tail light housing.
Rear left fog light bulb - L46- 12 V, P 21 W
Right reversing light bulb - M17- 12 V, P 21 W
Installing:
following:
gage.
6.4.4 Checking tail light in rear lid

The tail lights in rear lid ( rear left fog light bulb - L46- and right
reversing light bulb - M17- ) can be checked by the final control
⇒ page 424 .
6.5 Tail lights for Canada and USA

The tail lights in the side panel and rear lid on vehicles for Canada
and USA can be removed and installed in the same manner as
for RoW. A reversing light is installed in the left rear lid tail light
instead of a rear fog light with this version.
♦ Tail light in side panel (saloon) ⇒ page 255
♦ Tail light in rear lid (saloon) ⇒ page 258
♦ Tail light in side panel (Variant) ⇒ page 261
♦ Tail light in rear lid (Variant) ⇒ page 265

7 Number plate light
Note
The function of the number plate light can be tested using the final
control diagnosis of the onboard supply control unit - J519- .

7.1 Removing and installing bolted number

plate light - X- (saloon)
Removing:
– Remove securing bolts -1-, from number plate light - X- -2-.
– Carefully lever number plate light - X- out of bumper cover by
inserting a suitable screwdriver in the slot -arrow-.
7. Number plate light 269

– Lever lens -1- out of number plate light housing -2- in direction
of arrow using a suitable screwdriver.
Note
Ensure seal between lens and number plate light housing is not
damaged when levering out lens.
Number plate light - X- : festoon bulb 12 V, 5 W

Installing:
following:
When assembling number plate light, ensure lens seal is seated
correctly.
7.2 Removing and installing bolted number

plate light - X- (Variant)
Removing:
– Remove securing bolts -1-, from number plate light - X- -2-.
– Carefully remove lens with bulb from bumper cover.
Number plate light - X- : festoon bulb 12 V, 5 W
Installing:
following:
On installation, make sure the contacts at the bulb carrier and in
the bulb housing are clean.
7.3 Clipped number plate light - X-
7.3.1 Removing and installing clipped number

plate light
Removing:
Note
The removal and installation for the Variant and the saloon are
carried out in the same manner.
– Switch off ignition and all electrical consumers and remove

ignition key.

– Press retaining lug -arrow- onto number plate light until num‐
ber plate light can be removed from bumper cover (saloon) or
tailgate (Variant).

Installing:
following:
Note
Insert number plate light into bumper cover so that connector is

oriented to left side of vehicle.
– Check function of number plate light.
7.3.2 Removing and installing clipped number

plate light bulb
Removing:
ignition key.
– Remove number plate light ⇒ page 270 .
– To release bulb holder, turn it in direction of -arrow- and re‐
move it from number plate light.
Bulb for clipped number plate light: glass-base bulb 12 V, W 5 W
Installing:
7.4 Checking number plate light - X-

The number plate light - X- can be checked using final control
diagnosis for onboard supply control unit - J519- ⇒ page 424 .
7. Number plate light 271

8 Additional brake lights
Note
The function of the additional brake lights can be tested using the
final control diagnosis of the onboard supply control unit - J519- .

Note
♦ LED failure in additional brake lights (not USA and Canada):

♦ The individual LEDs (light-emitting diodes) in the additional
brake lights are comprised in groups of four LEDs and are
supplied with current in groups.
♦ The additional brake light is designed so that it can still meet
the legal requirements of the ECE regulations (Economic
Commission for Europe) should one of the LED groups fail to
operate. If a further LED group fails, these requirements are
no longer met according to the legislator.
♦ Due to the failure of one LED group, the intact LEDs are placed
under increased strain; it must be anticipated that further LED
groups will soon fail.
♦ If more than four individual LEDs in the additional brake light
have failed, the additional brake light must be renewed (repair
measure).
8.1 Tools
♦ Wedge - T10039/1-

♦ Torque screwdriver - V.A.G 1624-
8.2 Removing and installing high-level

brake light bulb - M25- (saloon)
The high-level brake light bulb - M25- is located on the top edge
of the rear window under the roof headliner end trim strip.
Note
♦ The high-level brake light bulb - M25- uses light emitting di‐
odes (LEDs).
♦ The high-level brake light bulb - M25- cannot be dismantled.
♦ In the event of damage, the complete high-level brake light
bulb - M25- must be renewed.
Removing:
– Unclip roof headliner end trim strip -4- downwards.
– Carefully push high-level brake light bulb - M25- -3- in direction
of arrow out of retainer rail -1-.
– Remove high-level brake light bulb - M25- from vehicle.
Installing:
Installation is carried out in the reverse sequence.

brake light bulb - M25- (Variant)
The high-level brake light bulb - M25- is located in the rear lid,
above the rear window.
Note
odes (LEDs).
8. Additional brake lights 273

Removing:
Note
When removing and installing components in visible locations

(switches, covers, trim and so on), mask over areas on which
lever-type tools ( wedge - T10039/1- , screwdriver) are applied,
using commercially available adhesive tape.

– To prevent damage to paintwork, stick a strip of commercially
available adhesive tape on paintwork of roof spoiler above
high-level brake light bulb - M25- .
Caution
Ensure the seal is not damaged when removing the additional

brake light.
– Insert wedge - T10039/1- between upper edge of high-level

brake light bulb - M25- and roof spoiler as shown in illustration.
– Press brake light downwards and unclip upper brake light
locking lugs to rear using wedge - T10039/1- .
– Then pull the high-level brake light bulb - M25- to rear out of
opening in the roof spoiler, as far as the connected wiring al‐
lows.
Note
If the high-level brake light bulb - M25- cannot be removed as

described, please contact the TSC or the importer.
– Release and disconnect connector -1- and remove high-level

brake light bulb - M25- -2-.
Installing:
Note
Ensure when installing the additional brake light bulb - M25- that
the seal is seated correctly. The seal must not form loops or be
damaged.
– Connect connector to brake light.

– Clip the brake light back into the roof spoiler starting at the
lower edge.

brake light bulb - M25- (Variant R36)
The high-level brake light bulb - M25- is located in the roof spoiler
over the rear window.

Note
odes (LEDs).
Removing:
ignition key.
– Remove roof spoiler ⇒ General body repairs, exterior; Rep.
gr. 66 ; Removing and installing roof spoiler .
– Pull cable feed seal out of retaining strip and disconnect con‐
nector.
– Remove the two bolts -2- from the inside of the roof spoiler.
– Release fastener -1- in direction of -arrow- and take additional
brake light bulb - M25- to rear out of roof spoiler.
Installing:
Note
When installing roof spoiler, ensure that cable feed seal is seated
correctly.
Specified torque for bolts -2- : 2 Nm
8.5 Checking high-level brake light bulb -

M25-
The high-level brake light bulb - M25- can be checked using final
control diagnosis for onboard supply control unit - J519-
⇒ page 424 .
8. Additional brake lights 275

9 Steering column switch up to 10/09
Caution

served ⇒ page 4 .
Note
♦ If a new steering column electronics control unit - J527- is in‐

stalled, it must be coded ⇒ page 280 .
♦ In the event of faults in the steering column switch, the coding
of the steering column electronics control unit - J527- must be
checked in final control diagnosis ⇒ page 280 .
The steering column electronics control unit - J527- is equipped
with self-diagnosis, which is designed to simplify fault finding.
9.1 Assembly overview - steering column switch

1 - Steering column combina‐

tion switch - E595-
❑ The individual switches
of the steering column
combination switch -
E595- form one unit and
it cannot be dismantled.
❑ Check via final control
diagnosis ⇒ page 280 .
2 - Windscreen wiper switch
❑ Part of steering column
E595- ⇒ page 282
3 - Airbag coil connector and
return ring with slip ring - F138-
⇒ page 281
4 - Segment sender for steer‐
ing angle sensor
⇒ page 282
5 - CCS switch - E45-
❑ Part of steering column
E595- ⇒ page 282
6 - Steering column electronics
⇒ page 278
7 - Securing bolt (T7)
8 - Turn signal switch - E2-
❑ Part of steering column combination switch - E595- ⇒ page 282
❑ Check via final control diagnosis ⇒ page 280 .
9.2 Removing and installing steering col‐

umn switch
Caution

served ⇒ page 4 .
Removing:
The following sequence must always be observed even if only
one component of the steering column switch is removed or re‐
newed.
9. Steering column switch up to 10/09 277


– Remove steering wheel ⇒ General body repairs, interior; Rep.
gr. 69 ; Airbag .
– Remove steering column trim ⇒ General body repairs, interior;
installing steering column trim .
Remove components of steering column switch in the following
sequence:
♦ Steering column electronics control unit - J527- ⇒ page 278
♦ Airbag coil connector and return ring with slip ring - F138-
⇒ page 281
♦ Segment sender for steering angle sensor ⇒ page 282
♦ Steering column combination switch - E595- ⇒ page 283
Installing:
9.3 Steering column electronics control unit

- J527-
9.3.1 Removing and installing steering col‐

umn electronics control unit - J527-
Note
♦ After new control unit has been installed, it must be coded

⇒ page 280 .
of the control unit must be checked ⇒ page 280 .
Removing:
gr. 69 ; Airbag .
– Remove securing bolt -2- on steering column electronics con‐
trol unit - J527- -1-.

– Release connector -1- on right side of control unit by pressing

the release button -2- in direction of arrow and pull connector
-1- off steering column electronics control unit - J527- -3-.
– Release connectors -2- and -3- on left side of control unit by

pressing the release buttons -4- and pull connectors -2- and
-3- off steering column electronics control unit - J527- -1-.
– Release fasteners -arrows- on right side of steering column

electronics control unit - J527- .
– Release fastener -arrow- on left side of steering column elec‐

tronics control unit - J527- .
– Carefully pull steering column electronics control unit - J527-
downwards off steering column combination switch - E595- .
Note
The connectors for airbag coil connector and return ring with slip
ring - F138- and steering angle sensor segment sender will be
disconnected automatically when pulling off.

– Release connector -1- by pulling on lock button -arrow A- and

pull connector -1- off steering column electronics control unit
- J527- .
– Pull locking bar -3- out of connector -2-.
– Unclip -arrow B- connector -2- and disconnect from steering
column electronics control unit - J527- .
Installing:
Note
Ensure when fitting the connector that none of the pins get bent
and that the connector engages audibly.
9.3.2 Coding steering column electronics con‐

trol unit - J527-
♦ Body
♦ Steering wheel electronics
♦ Steering wheel electronics functions
♦ Coding steering wheel electronics control unit
9.3.3 Steering column electronics control unit

- J527- final control diagnosis
♦ Body
♦ Steering wheel electronics final control diagnosis

9.4 Airbag coil connector and return ring

with slip ring - F138-
9.4.1 Removing and installing airbag coil con‐

nector and return ring with slip ring -
F138-
Removing:
Remove the following components in sequence:
gr. 69 ; Airbag .
– Remove steering column electronics control unit - J527-
⇒ page 278 .
Note
Coil connector should not be moved out of central position during

removal and road wheels should be in “straight-ahead” position.
– Slightly lift up both locking tabs -arrows- on airbag coil con‐

nector and return ring with slip ring - F138- -1- and pull airbag
coil connector and return ring with slip ring - F138- backwards
off steering column.
Installing:
Note
♦ During installation of coil connector, coil connector must be in

central position and road wheels must be in “straight-ahead”
position.
♦ Ensure the locking tabs engage correctly.
The central position (depending on manufacturer) of the coil con‐

nector is shown in the following diagram:

♦ The coloured strip (black rectangles) -arrow- must be located

in sight window -1-.
♦ The coloured roller (yellow) -arrow- must be located in sight
window -1-.
9.5 Segment sender for steering angle sen‐

sor
9.5.1 Removing and installing segment send‐

er for steering angle sensor
Removing:
gr. 69 ; Airbag .
⇒ page 278 .
– Remove airbag coil connector and return ring with slip ring -
F138- ⇒ page 281 .
– Release fastener -arrows- and pull segment sender for steer‐
ing angle sender -1- back off steering column switch unit.
Installing:
9.6 Steering column combination switch -

E595-
Depending on equipment, the steering column combination
switch - E595- comprises the following components and cannot
be dismantled in the event of repair:
♦ Turn signal switch - E2-
♦ Headlight dipper and flasher switch - E4-
♦ CCS switch - E45-
♦ Windscreen wiper switch - E-

♦ Rear window wiper switch - E34-

♦ Intermittent wiper switch - E22-
♦ Intermittent wiper regulator - E38-
♦ Windscreen washer pump switch (automatic wash/wipe and
headlight washer system) - E44-

umn combination switch - E595-
Removing:
gr. 69 ; Airbag .
⇒ page 278 .
– Remove airbag coil connector and return ring with slip ring -
F138- ⇒ page 281 .
– Remove segment sender for steering angle sensor
⇒ page 282 .
– Remove both bolts -arrows- from top side of steering column
combination switch - E595- .
– Pull steering column combination switch - E595- backwards
from steering column.
Installing:
⇒ page 335 .

9.6.2 Checking steering column combination

switch - E595-
Note
In the event of faults in the steering column combination switch -

E595- , the coding of the steering column electronics control unit
- J527- must be checked using final control diagnosis
⇒ page 280 .

10 Steering column switch, vehicles

from 11/09
10.1 General description
Caution
The removal and installation of individual components of the

steering column switch must be performed in a specified se‐
quence ⇒ page 286 .
The components of the steering column combination switch,

steering column electronics control unit and steering column
switch base are installed as 2 different versions depending on
equipment level (manufacturers: Valeo or Kostal). The visible
fastening of the steering column electronics control unit to the
steering column combination switch can be used to identify which
version is installed.
♦ Manufacturer: Valeo, 3 bolts
♦ Manufacturer: 1 bolt at bottom and 2 fasteners at top.
Note

The steering column electronics control unit - J527- is equipped
with self-diagnosis, which is designed to simplify fault finding.
For fault finding, use vehicle diagnosis, testing and information
system - VAS 5051A- in “Guided fault finding” mode.
10.2 Assembly overview - steering column

switch
Note
The components steering column electronics control unit - J527- ,

steering column combination switch - E595- and the steering col‐
umn switch base are available as different versions depending on
manufacturer (Valeo or Kostal). Illustration of assembly overview
shows Valeo version.
10. Steering column switch, vehicles from 11/09 285

1 - Steering column electronics

❑ Note removal and instal‐
lation sequence
⇒ page 286 .
(manufacturer: Valeo)
⇒ page 288
(manufacturer: Kostal)
⇒ page 289
2 - Steering column combina‐
tion switch - E595-
❑ Note removal and instal‐
lation sequence
⇒ page 286 .
⇒ page 291
⇒ page 292
3 - Securing bolts
10.3 Removal and installation sequence of

components of steering column switch
Caution

served ⇒ page 4 .
For removal of the complete steering column switch, inc. base,

the switch is dismantled and the steering lock housing is also re‐
moved. For assembly of the steering lock housing, new shear
bolts are required.
Even if just one component of the steering column switch is re‐
moved or renewed, the sequence described as follows must be
adhered to.
Removing:

WARNING
♦ Danger of the triggering of the airbag!

♦ Improper action on airbag unit may result in the triggering
of the airbag!
♦ Observe safety precautions when working on airbag ⇒
General body repairs, interior; Rep. gr. 69 ; Airbag; Safety
precautions when working on airbag .

gr. 69 ; Airbag .
Remove components of steering column switch in the following
sequence:
♦ Steering column electronics control unit - J527- ⇒ page 287
♦ Steering column combination switch - E595- ⇒ page 291
♦ Steering column switch base ⇒ page 292
Installing:
10.4 Steering column electronics control unit

- J527-
The steering column electronics control unit - J527- comprises the
following components and cannot be dismantled:
♦ Airbag coil connector and return ring with slip ring - F138-
♦ Steering angle sender - G85-
Note

stalled, the inserted transport protection must be removed
before installation.
of the steering column electronics control unit - J527- must be
checked ⇒ page 290 .
Removal and installation of steering column electronics control

unit - J527- are different, depending on manufacturer.
♦ Removing and installing steering column electronics control
unit - J527- (manufacturer: Valeo) ⇒ page 288
♦ Removing and installing steering column electronics control
unit - J527- (manufacturer: Kostal) ⇒ page 289


Removing:
Caution

WARNING

of the airbag!

gr. 69 ; Airbag .


– Depending on equipment level, release and disconnect con‐
nectors -1-, -2-, -3- and -4-.
Note
Coil connector on steering column electronics control unit - J527-

must not be twisted from its centre position. The front wheels must
be in “straight-ahead” position.
– Unscrew the 3 securing bolts -arrows- and pull off steering

column electronics control unit - J527- backwards from steer‐
ing column switch.
Installing:
Caution
Turn signal switch reset lever can break when control unit is
being installed.
Turn signal lever must be in 0 position when control unit is in‐
stalled so that reset lever is not extended.
– Push steering column electronics control unit - J527- straight

on steering column switch.
– Screw in and tighten the 3 securing bolts of steering column
electronics control unit - J527- to steering column switch mod‐
ule and tighten them to 1.5 Nm.
– Install all parts in reverse order of removal.

Removing:
Caution

WARNING

of the airbag!


gr. 69 ; Airbag .
– Depending on equipment level, release and disconnect con‐
nectors -1-, -2-, -3-, -4- and -5-.
– Unscrew securing bolt -arrow B-.
Note
Coil connector for steering column electronics on steering column

electronics control unit - J527- must not be twisted from its centre
position. The front wheels must be in “straight-ahead” position.
– Release both fasteners -arrows A- and pull off steering column

electronics control unit - J527- backwards from steering col‐
umn switch.
Installing:
Caution
Turn signal switch reset lever can break when control unit is
being installed.
Turn signal lever must be in 0 position when control unit is in‐
stalled so that reset lever is not extended.
– Push steering column electronics control unit - J527- straight

on steering column switch until it securely engages.
– Screw in securing bolts of steering column electronics control
unit - J527- to steering column switch module and tighten them
to 1.5 Nm.
10.4.3 Coding steering column electronics con‐

trol unit - J527-
– Connect vehicle diagnosis tester .
♦ Body
♦ Coding steering wheel electronics control unit

10.5 Steering column combination switch -

E595-
Depending on equipment, the steering column combination
switch - E595- comprises the following components and cannot
be dismantled:
♦ Turn signal switch - E2-
♦ Windscreen wiper switch - E-
♦ CCS switch - E45-
Removal and installation of steering column combination switch
are different, depending on manufacturer.
♦ Removing and installing steering column combination switch
- E595- (manufacturer: Valeo) ⇒ page 291
♦ Removing and installing steering column combination switch
- E595- (manufacturer: Kostal) ⇒ page 292

umn combination switch - E595- (man‐
ufacturer: Valeo)
Caution

Removing:
gr. 69 ; Airbag .
⇒ page 287 .
– Release both fasteners -arrows- and pull off complete steering
column combination switch - E595- straight backwards from
steering column switch base.
Installing:
– Push steering column combination switch - E595- straight into
guides on steering column switch base until it securely en‐
gages.


umn combination switch - E595- (man‐
ufacturer: Kostal)
Caution

Removing:
gr. 69 ; Airbag .
⇒ page 287 .
– Remove securing bolt -arrow- and pull off complete steering
column combination switch - E595- -1- straight backwards
from steering column switch base.
Installing:
– Push steering column combination switch - E595- straight into
guides on steering column switch base.
– Screw in securing bolt -arrow-.
10.6 Steering column switch carrier

Removal and installation of steering column switch carrier is dif‐
ferent, depending on manufacturer.
♦ Removing and installing steering column switch carrier (man‐
ufacturer: Valeo) ⇒ page 292
♦ Removing and installing steering column switch carrier (man‐
ufacturer: Kostal) ⇒ page 294

umn switch carrier (manufacturer: Va‐
leo)
Caution


♦ Angle hand drill

Removing:
Note
To remove steering column switch carrier -2-, shear-head bolts

-1- of steering lock housing must be drilled out. New shear-head
bolts are required for subsequent installation ⇒ Electronics parts
catalogue (ETKA) .
Caution
♦ Ensure that all the components mounted on the base have

been removed before drilling out the shear-head bolts.
♦ The drilling operation can cause swarf to penetrate the
adjacent components resulting in damage and/or mal‐
function!
♦ Adhere to the specified sequence when removing com‐
ponents of the steering column switch ⇒ page 286 .
Caution

served ⇒ page 4 .
Removing:
– Remove all components on the carrier in the prescribed se‐
The carrier can be removed once all the components mounted to
it have been removed:

– Drill out shear-head bolts -1- of steering lock housing -3-.
Note
Bolts M8 -1-, core diameter 6.8 mm
– Pull steering lock housing -3- and steering column switch base
-2- backwards off steering column.
– Take steering lock housing off steering column switch base.
Installing:
– Insert steering lock housing -3- into steering column switch

base -2-.
– Push steering column combination switch - E595- on steering
column switch base until it securely engages.
– Push pre-assembled unit composed of steering lock housing,
steering column switch base and steering column combination
switch - E595- straight onto stop on steering column and align
unit with threaded holes.
– Secure steering lock housing -3- to steering column using new
shear-head bolts -1-.
– Tighten new shear-head bolts -1- until head of bolt shears off.

umn switch carrier (manufacturer: Kos‐
tal)
Caution


♦ Angle hand drill

Removing:
Note
To remove steering column switch carrier -2-, shear-head bolts

-1- of steering lock housing must be drilled out. New shear-head
bolts are required for subsequent installation ⇒ Electronics parts
catalogue (ETKA) .
Caution
♦ Ensure that all the components mounted on the base have

been removed before drilling out the shear-head bolts.
♦ The drilling operation can cause swarf to penetrate the
adjacent components resulting in damage and/or mal‐
function!
♦ Adhere to the specified sequence when removing com‐
ponents of the steering column switch ⇒ page 286 .
Caution

served ⇒ page 4 .
Removing:
– Remove all components on the carrier in the prescribed se‐
The carrier can be removed once all the components mounted to
it have been removed:
– Drill out shear-head bolts -1- of steering lock housing -3-.
Note
Bolts M8 -1-, core diameter 6.8 mm
– Pull steering lock housing -3- and steering column switch base
-2- backwards off steering column.
– Take steering lock housing off steering column switch base.
Installing:

– Insert steering lock housing -3- into steering column switch

base -2-.
– Push steering column combination switch - E595- on steering
column switch base and screw in lower securing bolt.
– Push pre-assembled unit composed of steering lock housing,
steering column switch base and steering column combination
switch - E595- straight onto stop on steering column and align
unit with threaded holes.
– Secure steering lock housing -3- to steering column using new
shear-head bolts -1-.
– Tighten new shear-head bolts -1- until head of bolt shears off.

11 Ignition/starter switch and lock cylin‐

der
Note
System
11.1 Ignition/starter switch

The electric ignition lock for the Passat 2006 has a different de‐
sign and function and is now called electronic ignition lock - D9-
⇒ page 390 .
The electronic ignition lock is a single component and can be re‐
newed only as a complete unit.
The electronic ignition lock includes the following components:
♦ Entry and start authorisation switch - E415-
♦ Immobiliser reader unit - D1-
♦ Button illumination bulb - L76-
♦ Ignition key withdrawal lock solenoid - N376-
11.1.1 Removing and installing electronic igni‐

tion lock - D9-
– Removing and installing electronic ignition lock - D9-
⇒ page 391 .
11.2 Lock cylinder

The electronic ignition lock is no longer a part of the lock cylinder.
The function of the steering column lock is now performed by the
steering column lock control element - N360- as part of the elec‐
tronic steering column lock control unit - J764- ⇒ page 392 .
Vehicles with KESSY (Keyless Entry Start Stop System): the
steering column lock is activated by pulling the start button in the
ignition/starter switch out of position “S” and into position “locked”.
The start button can remain in position “locked” ⇒ Owner's Man‐
ual .
11. Ignition/starter switch and lock cylinder 297

12 Parking aid
Note
System
The Passat has an 8 channel parking aid with 4 ultrasonics sen‐
sors (parking aid sensors) in the rear bumper and 4 ultrasonics
sensors in the front bumper or radiator grille.
The parking aid system monitors the surrounding area via the ul‐
trasonic sensors in the front and rear bumpers. The acoustic
distance warning is provided by two warning buzzers in the vehi‐
cle interior.
The rear sensors are switched off automatically when a trailer is
hitched to the vehicle and the connector is plugged into the trailer
socket. The front sensors remain active.
The 8 channel parking aid comprises the following components:
♦ Parking aid control unit - J446-
♦ Front left parking aid sender - G255-
♦ Front centre left parking aid sender - G254-
♦ Front centre right parking aid sender - G253-
♦ Front right parking aid sender - G252-
♦ Rear left parking aid sender - G203-
♦ Rear centre left parking aid sender - G204-
♦ Rear centre right parking aid sender - G205-
♦ Rear right parking aid sender - G206-
♦ Front parking aid warning buzzer - H22-
♦ Rear parking aid warning buzzer - H15-
♦ Parking aid button - E266-
♦ Parking aid switch illumination bulb - L117-
Function:
The system performs a self-test after the ignition is switched on;
this is completed in less than one second. From this point on‐
wards the control unit is permanently operational and the distance
sensing function is active.
A brief audible signal is given and the warning lamp lights up when
the parking aid system is ready. If a fault is detected, a continuous
audible signal is given for 5 seconds and the parking aid warning
lamp flashes.
The intervals between the warning signals become proportionally
shorter as the distance decreases. At distances of less than 30

cm the warning signals merge into a continuous tone. Special sit‐

uation: driving parallel to a wall = no signal
The park assist steering control unit - J446- is equipped with self-
diagnosis, which makes fault finding easier.
Perform final control diagnosis to check parking aid system
⇒ page 301 .
12.2 Assembly overview - parking aid
1 - Parking aid senders in rear

bumper cover
❑ Rear left parking aid
sender - G203- in rear
bumper cover
❑ Rear centre left parking
aid sender - G204- in
rear bumper cover
❑ Rear centre right park‐
ing aid sender - G205- in
rear bumper cover
❑ Rear right parking aid
sender - G206- in rear
bumper cover
(saloon) ⇒ page 303 .
(Variant) ⇒ page 303 .
❑ Bonding sender retainer
in cases of repair
⇒ page 305 .
2 - Rear parking aid warning
buzzer - H15-
(saloon) ⇒ page 304 .
(Variant) ⇒ page 305 .
3 - Parking aid button - E266-
❑ In centre console next to
gear lever
⇒ page 305
4 - Front parking aid warning
buzzer - H22-
5 - Parking aid senders in front bumper and radiator grille
❑ Front left parking aid sender - G255-
❑ Front centre left parking aid sender - G254- (in radiator grille)
❑ Front centre right parking aid sender - G253- (in radiator grille)
❑ Front right parking aid sender - G252-
12. Parking aid 299

❑ Bonding sender retainer in cases of repair ⇒ page 305 .
6 - Parking aid control unit - J446-
❑ Behind side panel trim on right in luggage compartment ► 04/2008.
❑ Driver side above fuse holder 05/2008 ►.
❑ Removing and installing ⇒ page 300 .
12.3 Parking aid control unit - J446- and park

assist steering control unit - J791-
12.3.1 Removing and installing parking aid

control unit - J446- and park assist steer‐
ing control unit - J791- ► 05/2008
The parking aid control unit - J446- is located behind the right
luggage compartment side panel trim.
Removing:
– Open cover in right luggage compartment trim panel.
Note
For reasons of clarity, the location of the parking aid control unit
is shown with the luggage compartment trim panel removed.
– Release and disconnect connectors -2-.

– Press the locking lugs of the retaining pin -arrows- on both
sides of the parking aid control unit - J446- together and pull
parking aid control unit - J446- -1- off the retaining pins.
Installing:

12.3.2 Removing and installing parking aid

control unit - J446- and park assist steer‐
ing control unit - J791- 05/2008 ►
The parking aid control unit - J446- is located above the fuse
holder -arrow- on the driver side.
– Switch off ignition and all electrical consumers and position
ignition key or start button in position 0 (pre-detent).
– Open and remove storage compartment under steering wheel.
– Open cover of fuse holder.
– Separate connector.
– Unclip control unit from holder.
Note
For reasons of clarity, the location of the control unit is shown with
a partly dismantled dash panel.
– Release spreader rivet, disconnect connectors and remove

control unit.
Installing:
12.3.3 Parking aid control unit - J446- final con‐

trol diagnosis
The final control diagnosis can be used to check the following
components:
♦ Rear parking aid warning buzzer - H15-
♦ Parking aid warning lamp - K136-
♦ Body
♦ General body repairs
♦ Parking aid
♦ Parking aid functions
♦ Parking aid final control diagnosis
12.3.4 Coding parking aid control unit - J446-

The parking aid control unit - J446- can be set to suit the config‐
uration in a particular vehicle by coding it accordingly.
12. Parking aid 301

♦ Body
♦ Parking aid
♦ Parking aid functions
♦ Coding parking aid
12.3.5 Pin assignment of parking aid control

unit - J446-
Refer to current flow diagram for pin assignment of parking aid
control unit - J446- ⇒ Current flow diagrams, Electrical fault finding
and Fitting locations.
12.4 Front parking aid senders
12.4.1 Removing and installing front parking

aid senders
Removal and installation of parking aid senders in the front bump‐
er and radiator grille are performed in the same manner.
Removing:
gr. 66 ; Radiator grille; Trim strips and trim; Assembly over‐
view - radiator grille for PDC in radiator grille) .
– Remove front turn signal ⇒ page 248 .
– Press both locking lugs -2- on sender retainer outwards and
pull parking aid sender -1- back out of sender retainer.
Note
Ensure when removing the sender that the isolation ring (black
silicone ring) does not remain in sender retainer.
Installing:
following:
Note
♦ Ensure when inserting the sender in the sender retainer that

the isolation ring (black silicone ring) is seated correctly on the
sender head.
♦ Both locking lugs of sender retainer must audibly engage
when installing the sender.

12.5 Rear parking aid senders
12.5.1 Removing and installing rear parking aid

senders (saloon)
Removing:
– Remove rear bumper cover ⇒ General body repairs, exterior;
Rep. gr. 63 ; Rear bumper; Removing and installing bumper
cover .
Removal and installation of parking aid senders in the rear bump‐
er are performed in the same manner as for the front bumper
⇒ page 302 .
Installing:
following:
Note

sender head.

senders (Variant)
Removing:
Rep. gr. 63 ; Rear bumper (Variant); Removing and installing
bumper cover .
Removal and installation of parking aid senders in the rear bump‐
er are performed in the same manner as for the front bumper
⇒ page 302 .
Installing:
following:
Note

sender head.
12. Parking aid 303

12.6 Parking aid warning buzzer

aid warning buzzer - H22-
The front parking aid warning buzzer - H22- is located under the
dash panel in the front left footwell and is secured on the console
for the relay carrier.
Removing:
– Remove cover under dash panel in driver footwell ⇒ General
body repairs, interior; Rep. gr. 68 ; Covers; Footwell; Remov‐
ing driver side .
– Release both spreader rivets -arrows-.
– Release and disconnect connector -1- and remove front park‐
ing aid warning buzzer - H22- -2- from vehicle.
Installing:
Note
Coding, basic setting and adaption are not necessary if the front
parking aid warning buzzer - H22- is renewed.

warning buzzer - H15- (saloon)
The rear parking aid warning buzzer - H15- is located on the right
under the rear shelf.
Removing:
– Remove rear shelf ⇒ General body repairs, interior; Rep. gr.
68 ; Pillars and side panel trim; Removing and installing rear
shelf .
– Release spreader rivets -arrows- and remove rear parking aid
warning buzzer - H15- -1- from vehicle.
Installing:
Note
Coding, basic setting and adaption are not necessary if the rear


warning buzzer - H15- (Variant)
The rear parking aid warning buzzer - H15- is located behind the
rear right side panel trim near the seat belt mounting.
Removing:
– Remove right side trim panel in luggage compartment ⇒ Gen‐
eral body repairs, interior; Rep. gr. 68 ; Load, luggage com‐
partment trim .
– Release spreader rivets -arrows- and remove rear parking aid
warning buzzer - H15- -2- from vehicle.
Installing:
Note
12.7 Parking aid button - E266-

The parking aid button - E266- is located in the centre console
next to the gearstick/gear selector lever.
12.7.1 Removing and installing parking aid but‐

ton - E266-
– Removing and installing parking aid button - E266-
⇒ page 380
12.8 Bonding sender retainer for parking aid

and park assist steering in cases of re‐
pair
If a new bumper cover is installed then the respective parking aid
sender retainers must be bonded to the inside of the bumper cov‐
er at the respective locations as marked. Before bonding, the
sender retainers and the senders must be painted in the colour
of the bumper. The following prerequisites must be adhered to
when painting the sender retainers and the senders to ensure the
function of the parking aid system is not adversely affected. The
preparation of the bonding surfaces and the bonding process
must be undertaken considering the following processes.
12. Parking aid 305

12.8.1 Painting sender retainers and senders

Painting sender retainer:
– Remove grease from sender bracket in area to be painted
-1- with isopropanol (isopropyl alcohol).
– Paint sender bracket in area to be painted -1- in colour of
bumper cover.
Note
♦ Dimension -A- for the painted area on the inside of the sender
retainer must not exceed 2.5 mm.
♦ Only paint inside of sender bracket in areas as shown. If these
instructions are not observed the installation may be difficult
and the function of the parking aid system may be affected.
Painting sender:
– Remove isolation ring (black silicone ring) from sender head.
– Degrease black sender head -1- in area to be painted -2- with

isopropanol (isopropyl alcohol).
– Paint sender in area to be painted -2- in colour of bumper cov‐
er.
Note
Dimension -B- for the painted area must not exceed 3 mm (+

maximum 2 mm).
– Fit isolation ring (black silicone ring) on sender head again

once paint has dried.
12.8.2 Allocating sensor retainer to respective

location in bumper cover and radiator
grille
The sender retainers are available in different forms and must be
allocated to the respective location in the bumper cover or radiator
grille. The sender retainers are marked on the inside with char‐
acters -arrow- to simplify the allocation. Note the position of the
sender connector in the respective allocation.

Allocating sender retainer to location on inside of front bumper

cover and radiator grille:
Retainer letter:
A - left centre (in radiator grille)
B - right centre (in radiator grille)
C - right outer
D - left outer
Allocating sender retainer to location on inside of rear bumper

cover (saloon):
Retainer letter:
A - left centre
B - right centre
C - right outer
D - left outer
Allocating sender retainer to location on inside of rear bumper

cover (Variant):
Retainer letter:
A - left centre
B - right centre
C - right outer
D - left outer
12.8.3 Bonding sender bracket in bumper cov‐

er
The bonding process for the sender retainers in the front and rear
bumper covers is performed in the same manner. The bonding
area on the inside of the bumper cover is marked as a field around
the punched hole to assist in aligning the sender retainer during
the bonding process. Ensure that the material temperature of the
bumper cover and the sender retainer lies between 15 °C and 25
°C.
12. Parking aid 307

– Clean the marked bonding areas -1- on the inside of the bump‐
er cover thoroughly with isopropanol (isopropyl alcohol).
– Apply adhesion promoter “Scotchmount 4298” evenly to
marked bonding area -1-
– Allow adhesion promoter to flash-off for approx. 5 minutes.
– Note correct position for bonding sender bracket
⇒ page 306 .
– Peel both protective foils off bonding surface of sender bracket
-2- until a grey surface appears.
– Align sender retainer -2- in marked bonding area -1- so that a
uniform edge of approx. 3 mm is created.
Note
Ensure that the cut-out for the sender connector in the sender
bracket is pointing in the correct direction as shown in the re‐
spective allocation. The sender wiring is too short if the sender
bracket is fitted incorrectly.
– Press sender bracket -2- onto bumper cover for approx. 10

seconds using a high pressure.
Note
The pressure and the period are critical for the bonding proper‐
ties!
12.8.4 Bonding sender retainer in radiator grille

Ensure when bonding the sender retainer in the radiator grille that
the sender retainer is aligned centrally in the punched hole in the
radiator grille as the sender retainer does not have a shoulder. If
the sender retainer is not aligned exactly centrally in the punched
hole in the radiator grille the isolation ring (black silicone ring) will
be under pressure from the chrome sender ring, once installed.
This may adversely affect the function of the parking aid system.
Ensure the material temperature of the radiator grille and the
sender retainer lies between 15 °C and 25 °C.
– Clean the bonding areas on the inside of the radiator grille
thoroughly with isopropanol (isopropyl alcohol).
– Apply adhesion promoter “Scotchmount 4298” evenly to bond‐
ing area around punched hole.
– Allow adhesion promoter to flash-off for approx. 5 minutes.
– Note correct position for bonding sender bracket
⇒ page 306 .
– Insert chrome sender into sensor retainer until both locking
devices audibly engage.
– Peel both protective foils off bonding surface of sender retainer
until a grey surface appears
– Align chrome sender head exactly centrally in punched hole
in radiator grille.

Note
If the sender head is not aligned exactly centrally in the punched

hole in the radiator grille, the isolation ring (black silicone ring) will
be under pressure from the chrome sender ring, once installed,
which may adversely affect the function of the parking aid system.
– Press sender retainer onto radiator grille for approx. 10 sec‐

onds using a high pressure.
Note
The pressure and the period are critical for the bonding proper‐
ties!
12. Parking aid 309

13 Park assist steering (PAS)
Note
♦ When handling complaints, it is essential to understand the

function and operation of the park assist steering.
♦ Additional information ⇒ Owner's manual
The park assist steering supports the driver when reversing into
a parallel parking space on the driver or passenger side. When
the park assist steering is activated and the vehicle drives by at
a speed of less than 35 km/h, the side of the road is measured by
ultrasonic sensors searching for a suitable parking space. Once
a parking space has been reliably detected, the park assist steer‐
ing requests the driver to continue passing by the parking space
until the vehicle is in a position from which rapid parking is pos‐
sible. When reverse gear is engaged, the park assist steering
undertakes lateral guidance of the vehicle by actuating the EPS
(electronic power steering) and steers the vehicle into the parking
space in one movement along a calculated, nominal path. The
driver maintains operation of the pedal cluster (accelerator,
clutch, brake) and longitudinal vehicle guidance, and therefore
determines the parking speed. During the parking process, the
park assist steering sensors are used together with the parking
aid senders to monitor proximity.
The following conditions lead to abortion of the parking process
with the park assist steering:
♦ The park assist steering is switched off via the park assist
steering button - E581- .
♦ Ignition is switched off
♦ Parking speed too high (>7 km/h)
♦ Steering intervention by driver during parking process
♦ Disengagement of reverse gear
♦ Vehicle standstill time limit exceeded (approx. 30 s)
♦ ESP switched off or ESP intervention
♦ TCS intervention
♦ Trailer attached to vehicle coupling
♦ Front parking aid (PDC) is switched on.
♦ Sensors detect a status which endangers secure determina‐
tion of the vehicle position.
♦ System malfunction

WARNING
♦ Responsibility during parking is borne by the driver.

♦ The park assist steering cannot replace the driver's atten‐
tiveness.
♦ The sensors have blind spots, in which persons and ob‐
jects can not be registered.
♦ Pay particular attention to small children and animals, as
these are not always detected by the sensors.
The park assist steering consists of:

♦ Park assist steering control unit - J791-
♦ Park assist steering button - E581-
♦ Front left sender for park assist steering on left side of vehicle
- G568-
♦ Front right sender for park assist steering on right side of ve‐
hicle - G569-
The park assist steering features self-diagnosis to facilitate fault
finding.
system in “Guided fault finding” mode.
To check the park assist steering as a whole, perform final control
diagnosis.
13.2 Assembly overview of park assist steering
13. Park assist steering (PAS) 311

1 - Front left sender for park

assist steering on left side of
vehicle - G568-
❑ In front bumper cover
⇒ page 314
❑ Renew sender and
sender retainer in the
event of repair
⇒ page 305 .
2 - Front left parking aid sender
- G255-
⇒ page 314
event of repair
⇒ page 305 .
3 - Front centre left parking aid
sender - G254-
❑ In radiator grille
⇒ page 314
event of repair
⇒ page 305 .
4 - Front centre right parking
aid sender - G253-
❑ In radiator grille
❑ Renew sender and sender retainer in the event of repair ⇒ page 305 .
5 - Front right parking aid sender - G252-
6 - Front right sender for park assist steering on right side of vehicle - G569-
7 - Front parking aid warning buzzer - H22-
❑ In driver side footwell, on left side of dash panel behind relay carrier
❑ Adjusting volume ⇒ page 317
❑ Adjusting pitch ⇒ page 317

8 - Front parking aid button - E266-

❑ In centre console storage compartment in front of gearshift lever.
9 - Park assist steering button - E581-
❑ In centre console storage compartment in front of gearshift lever.
10 - Park assist steering control unit - J791-
❑ Driver footwell above the fuse holder
❑ Securing bolt specified torque: 5 Nm
13.3 Park assist steering control unit - J791-

The park assist steering control unit - J791- is located in the driver
footwell above the fuse holder. In vehicles with front parking aid
or Park Assist, the parking aid functions are simultaneously con‐
trolled by the Park Assist control unit .
13.3.1 Coding park assist steering control unit

- J791-
♦ Body
♦ Park assist steering (PAS)
♦ Park assist steering functions
♦ Coding park assist steering.
13.4 Front parking aid sender and park assist

steering sender
The front parking aid sender and the park assist steering sender
are installed in the front bumper cover. The two park assist steer‐
ing senders are mounted at the outermost, lateral positions of the
bumper cover, and are used to measure proximity during the
parking process, together with the parking aid senders.
Note
If a new front bumper cover or a new protective radiator grille is

installed, the sender retainers must be bonded into the bumper
cover or protective radiator grille under consideration of defined
process steps ⇒ page 305 .


aid sender and park assist steering
sender
The following six senders are located in the front bumper cover:
♦ Front left sender for park assist steering on left side of vehicle
- G568-
♦ Front right sender for park assist steering on right side of ve‐
hicle - G569-
Note
Removal and installation of the front parking aid senders and the
park assist steering senders is carried out in the same way and
is described as follows for just one sender.
Removing:
ignition key.
Caution
The order for removing the senders must be adhered to under

all circumstances.
The sender may otherwise be damaged. Fractures may occur
if too much pressure is applied to the sender, and this may
cause the sender to fail.
First remove the senders from the brackets and then discon‐
nect the sender's connector.

– Release locking lugs -arrows- on sender retainer and pull
sender -1- with connector still joined out of bumper cover.
Note
♦ When removing the sender, make sure that the isolation ring
(black silicone ring) on the sender head does not remain in the
bracket or become lost.
♦ Expanding the isolation ring must be avoided under all cir‐
cumstances.

– Release and disconnect connector -2- and remove sender

-1-.
Installing:
following:
Caution
Function problems could occur if an incorrect or damaged iso‐

lation ring is used.
Expanding the isolation ring must be avoided under all circum‐
stances.
Renew damaged isolation rings and always ensure that the
correct isolation ring is fitted.
Note
As the front parking aid sender and the park assist steering send‐
ers have sender heads of different lengths, isolation rings of
different heights are also installed.
– Check whether the correct isolation ring is installed on the

sender head.
Type of sender Isolation ring height dimen‐
sion -B-
Front parking aid senders 5.7 mm
Park assist steering senders 9.05 mm
– If necessary, renew the sender's isolation ring -1-.
Note
♦ When mounting the sender, make sure that the isolation ring
is correctly mounted on the sender head and does not ride or
roll up on insertion into the sender retainer.
– After installing the sender, check that the sender is correctly

seated in the bracket. Visible on the outer side of the bumper,
dimension -a- of the ring gap between the sender head and
bumper cover must be even all around.

13.4.2 Checking front parking aid sender and

park assist steering senders
♦ Body
♦ Parking aid sender, park assist steering sender
13.5 Park assist steering button - E581-

The park assist steering button is located in the centre console
storage compartment in front of the gear lever. It contains the
warning light for park assist steering - K241- and cannot be dis‐
assembled any further.
13.5.1 Removing and installing park assist

steering button - E581-
Removal and installation of the park assist steering button - E581-
is carried out in the same way as for all buttons in the centre
console trim and are described in chapter ⇒ page 380 .
13.5.2 Checking park assist steering button -

E581-
♦ Body
♦ Park assist steering button
13.6 Front parking aid warning buzzer - H22-

The front parking aid warning buzzer - H22- is located in the driver
side footwell, behind the left dash panel relay carrier.

aid warning buzzer - H22-
Removing:
ignition key.
– Remove left dash panel relay carrier ⇒ page 304 .

– Pull out pins of both expansion rivets -arrows- and remove

front parking aid warning buzzer - H22- -1- under considera‐
tion of connected line lengths.
– Release and disconnect connector -arrow- and remove front

parking aid warning buzzer - H22- -1- from vehicle.
Installing:
13.6.2 Adjusting volume of front parking aid

warning buzzer - H22-
♦ Body
♦ Adjusting volume of front parking aid warning buzzer.
13.6.3 Adjusting pitch of front parking aid warn‐

ing buzzer - H22-
♦ Body
♦ Adjusting pitch of front parking aid warning buzzer.

13.7 Rear parking aid warning buzzer - H15-

(vehicles with park assist steering)
In vehicles with front parking aid or park assist steering, the park‐
ing aid functions are controlled by the park assist steering control
unit - J791- . Due to this reason, adaptations to the rear parking
aid warning buzzer - H15- in vehicles with front parking aid or park
assist steering are carried out via the park assist steering control
unit - J791- .

warning buzzer - H15- (vehicles with
park assist steering)
Removal and installation of rear parking aid warning buzzer -
H15- , saloon ⇒ page 304 .
Removal and installation of rear parking aid warning buzzer -
H15- , Variant ⇒ page 305 .
13.7.2 Adjusting volume of rear parking aid

warning buzzer - H15-
♦ Body
♦ Adjusting volume of rear parking aid warning buzzer.
13.7.3 Adjusting pitch of rear parking aid warn‐

ing buzzer - H15-
♦ Body
♦ Adjusting pitch of rear parking aid warning buzzer.

14 Entry and start authorisation
Caution

⇒ page 4 .
Note
System
⇒ Self-study programme No. 356 ; The Passat Variant 2006
⇒ Self-study programme No. 273 ; The Phaeton - Convenience
and Safety Electronics
tions
The access and start authorisation system is equipped with self-
diagnosis which makes fault finding easier.
All faults concerning the entry and start authorisation system are
output via the convenience system central control unit - J393- .

KESSY (Keyless Entry Start Stop System) controls keyless un‐
locking, locking and starting of the vehicle.
Opening:
The ID sender in the ignition key must be within the detection
range of a locking point (approx. 1.5 metres). The proximity sen‐
sor on the inside of the door handle is activated when the door
handle is touched. The ID sender in the ignition key is read and
the door is immediately unlocked on valid identification. Pulling
the door handle will open the door.
Starting:
The ID sender in the ignition key must be located in the interior of
the vehicle. The ID sender in the ignition key is read when the
start button is pushed into the second detent of the electronic ig‐
nition lock; steering release and start release are authorised in
the event of valid identification.
Starting the engine with the start button in the electronic ignition
lock is only possible when a valid ID sender is somewhere in the
vehicle interior.
Locking:
The ID sender in the ignition key must be within the detection
range of a locking point (approx. 1.5 metres). The locking sensor
14. Entry and start authorisation 319

is activated when the locking sensor on the outside of the door

handle is touched. The ID sender in the ignition key is read and
the vehicle is locked in the event of valid identification.
Ignition key:
The ignition key is designed without a key bit, as, for the first time,
the vehicle is started via a pushing motion not with a turning mo‐
tion. In vehicles equipped with Kessy, the switching processes in
the ignition lock are carried out with a start button. This start button
remains in the ignition lock and only functions together with a valid
ID sender in the radio remote control ignition key. The various
terminal voltages (term. S, term. 15) and the starting process are
switched on by pushing the start button in the electronic ignition
lock - D9- . The following switch positions are possible via pushing
the start button:
♦ P0 - off (pre-detent)
♦ P1 - S contact on
♦ P2 - terminal 15 on
♦ P3 - terminal 15 drive (after the starting process, the ignition
key automatically springs back to this position)
All functions concerning the entry and start authorisation are con‐
trolled via the convenience system central control unit - J393-
⇒ page 430 .
14.2 Emergency starting when communica‐

tion between ID sender and control unit
is defective
In the case of defective communication between the ID sender in
the start button and the convenience system central control unit
- J393- (e.g. dead battery in the start button), the engine can be
started using the radio remote control ignition key.
– Remove start button from electronic ignition lock.
– For this, release the locking pin -1- by pulling the slide
-arrow- on the underside to rear and pull the start button -2-
out of the electronic ignition lock.
– Insert the radio remote control ignition key into the electronic
ignition lock.
The ID sender in the ignition key is identified by the transponder
in the electronic ignition lock, and steering column release and
start release are issued.
The start procedure is performed in the same way as with the start
button.
Note
Ensure that the locking pin -1- points up if the start button is re‐
inserted into the electronic ignition lock. Otherwise the locking pin
will not engage in the ignition lock.
14.3 Electronic ignition lock - D9-

The ignition lock of the Passat 2006 is now known as the elec‐
tronic ignition lock - D9- .
All faults concerning the electronic ignition lock - D9- are output
via the convenience system central control unit - J393- .

The electronic ignition lock - D9- is a single component and can

be renewed only as a complete unit.
The electric ignition lock - D9- includes the following components
(depending on optional equipment):
♦ Ignition key withdrawal lock solenoid - N376- (vehicles with
automatic gearbox only)

tion lock - D9-
– Removing and installing electronic ignition lock - D9-
⇒ page 391 .
14.4 Convenience system central control unit

- J393-
The convenience system central control unit - J393- is located
behind the glove compartment on the front passenger side.
All functions concerning the entry and start authorisation are con‐
trolled via the convenience system central control unit - J393-
⇒ page 430 .
14.4.1 Removing and installing convenience

system central control unit - J393-
After renewing the convenience system central control unit -
J393- , the “entry and start authorisation” system must be adap‐
ted.
Note
♦ The procedure must always be carried out for reading the co‐
des stored in the “convenience system central control unit” if
the convenience system central control unit - J393- is to be
renewed ⇒ page 434 .
♦ After renewing the convenience system central control unit -
J393- , the convenience system central control unit's other
functions, such as “immobiliser”, “anti-theft alarm”, “entry and
start authorisation”, “tyre pressure monitor” and the central
locking system keys must also be adapted depending on
equipment.
♦ Start by adapting the immobiliser ( ⇒ page 390 ) and continue,
in any sequence, with the further functions of the convenience
system central control unit - J393- .
Removing and installing convenience system central control unit

- J393- ⇒ page 432 .
14.5 Entry and start authorisation aerials and

sensors
14.5.1 Assembly overview - entry and start au‐

thorisation aerials and sensors
The illustration shows the fitting locations in the Passat saloon.
The fitting locations in the Passat Variant are identical. Item
⇒ Item 4 (page 322) is not fitted in the Variant.

1 - Convenience system cen‐

tral control unit - J393-
❑ Fitting location: behind
glove compartment on
front passenger side
⇒ page 432
❑ Renewing and/or cod‐
ing convenience system
central control unit -
J393- ⇒ page 434
2 - Front passenger side door
exterior handle
The following components are
integrated into the front pas‐
senger side door exterior han‐
dle:
♦ Front passenger door exte‐
rior handle touch sensor -
G416-
♦ Front passenger side aerial
for entry and start authori‐
sation - R135-
Removing and installing front
passenger side door exterior
handle ⇒ page 324 .
❑ Checking front passen‐
ger side aerial for entry
and start authorisation -
R135- ⇒ page 331
3 - Rear right door exterior han‐
dle
The following components are
integrated into the rear right
door exterior handle:
♦ Approach sensor
♦ Locking sensor
❑ Removing and installing rear right door exterior handle ⇒ page 325
❑ Checking rear right door exterior door handle touch sensor - G418- ⇒ page 333 .
4 - Entry and start authorisation aerial 3 in interior - R154-
Note
Entry and start authorisation aerial 3

in interior - R154- is only installed in
the Passat saloon (not installed in
Passat Variant).
❑ Location in saloon: under rear shelf
❑ Checking entry and start authorisation aerial 3 in interior - R154- ⇒ page 332
5 - Rear bumper aerial for entry and start authorisation - R136-
❑ Fitting location: behind rear bumper cover
❑ Checking rear bumper aerial for entry and start authorisation - R136- ⇒ page 331
6 - Luggage compartment aerial for entry and start authorisation - R137-
❑ Fitting location: central in luggage compartment before the spare wheel recess

❑ Checking luggage compartment aerial for entry and start authorisation - R137- ⇒ page 331
7 - Rear left door exterior handle
The following components are integrated into the rear left door exterior handle:
♦ Approach sensor
♦ Locking sensor
❑ Removing and installing rear left door exterior handle ⇒ page 324
❑ Checking rear left door exterior door handle touch sensor - G417- ⇒ page 333
8 - Driver side door exterior handle
The following components are integrated into the driver side door exterior handle:
♦ Driver door exterior handle touch sensor - G415-
♦ Driver side aerial for entry and start authorisation - R134-
❑ Removing and installing driver side door exterior handle ⇒ page 323
❑ Checking driver door exterior handle touch sensor - G415- ⇒ page 332
❑ Checking driver side aerial for entry and start authorisation - R134- ⇒ page 330
9 - Interior aerial 2 for entry and start authorisation - R139-
❑ Fitting location: on rear section of centre console before the kick plate of the rear bench seat
10 - Interior aerial 1 for entry and start authorisation - R138-
❑ Fitting location: between the front seats on the centre tunnel
14.5.2 Removing and installing driver side door

exterior handle
The following components are integrated into the driver side door
exterior handle:
Note
♦ In the event of a fault, the complete door exterior handle must

always be replaced.
♦ Coding, basic setting and adaption are not necessary if the
door exterior handle is replaced. Clear the fault entry created
in the fault memory via “Guided fault finding” with vehicle di‐
agnosis tester ⇒ page 330 or ⇒ page 332 .
Removing:
– Remove front left exterior door handle ⇒ General body re‐
pairs, exterior; Rep. gr. 57 ; Assembly overview - door handle
and lock .
Installing:

14.5.3 Removing and installing front passenger

side door exterior handle
The following components are integrated into the front passenger
side door exterior handle:
♦ Front passenger door exterior handle touch sensor - G416-
♦ Front passenger side aerial for entry and start authorisation -
R135-
Note

always be replaced.
agnosis tester ⇒ page 331 or ⇒ page 333
Removing:
– Remove front right exterior door handle ⇒ General body re‐
and lock .
Installing:
14.5.4 Removing and installing rear left door

exterior handle
The following components are integrated into the rear left door
exterior handle:
Note

always be replaced.
agnosis tester ⇒ page 330 .
Removing:
– Remove rear left exterior door handle ⇒ General body repairs,
exterior; Rep. gr. 58 ; Assembly overview - door handle and
lock .
Installing:

14.5.5 Removing and installing rear right door

exterior handle
The following components are integrated into the rear right door
exterior handle:
R135-
Note

always be replaced.
agnosis tester ⇒ page 331 .
Removing:
– Remove rear right exterior door handle ⇒ General body re‐
and lock .
Installing:
14.5.6 Removing and installing rear bumper

aerial for entry and start authorisation -
R136-
The rear bumper aerial for entry and start authorisation - R136-
is located behind the rear bumper cover.
Note
bumper aerial for entry and start authorisation - R136- is replaced.
Clear the fault entry created in the fault memory via “Guided fault
finding” with vehicle diagnosis tester ⇒ page 331 .
Removing:
Rep. gr. 63 ; Rear bumper cover .

– Unclip rear bumper aerial for entry and start authorisation -

R136- -1- from lower section of bumper cover, taking connec‐
ted wiring length into consideration.
– Release and disconnect connector -2- and remove rear bump‐
er aerial for entry and start authorisation - R136- -1- from
vehicle.
Installing:
following:
– Reconnect connector -2- to rear bumper aerial for entry and

start authorisation - R136- -1-, ensure it engages.
– First insert rear bumper aerial for entry and start authorisation
- R136- -1- into mounting in lower section of bumper cover,
then push it into it's final position until it engages.
14.5.7 Removing and installing interior aerial 1

for entry and start authorisation - R138-
The interior aerial 1 for entry and start authorisation - R138- is
located between the front seats under the front section of the
centre console.
Note
Further coding, basic setting and adaption are not necessary if

the interior aerial 1 for entry and start authorisation - R138- is
replaced. Clear the fault entry created in the fault memory via
“Guided fault finding” with vehicle diagnosis tester ⇒ page 331 .
Removing:
Note
The alignment and exact positioning of the aerials is essential for

their function. Mark the exact position and alignment of the aerial
to the interior before removing the aerial. Align and secure in
original position when installing. The thickness of the adhesive
pad on the aerials is a part of its functionality. Do not use a com‐
mercial type adhesive to restick if the adhesive bonding of an
aerial is insecure. Install a new aerial with new adhesive pad in
this case. Non observance will cause the KESSY system to mal‐
function.

– Remove centre console ⇒ General body repairs, interior; Rep.
gr. 68 ; Removing and installing base version of centre con‐
sole .

Note
The vehicle carpet is not shown in the figure for reasons of clarity.
– Release and disconnect connector -2- and release the adhe‐

sive bonding of the interior aerial 1 for entry and start author‐
isation - R138- -1-.
– Remove the interior aerial 1 for entry and start authorisation -
R138- -1- from the vehicle.
Installing:
following:
– Insert connector -2- into interior aerial 1 for entry and start au‐
thorisation - R138- -1- until it engages.
– Align and bond interior aerial 1 for entry and start authorisation
- R138- in position, marked before removal, on centre console.

The interior aerial 2 for entry and start authorisation - R139- is
located on the rear section of the centre console, before the kick
plate for the rear bench seat.
Note

replaced. Clear the fault entry created in the fault memory via
Removing:
Note

function.

– Remove rear seat ⇒ General body repairs, interior; Rep. gr.
72 ; Rear seat .
– Remove rear sill entry mouldings sufficiently to fold rear carpet
forwards to gain access to interior aerial 2 for entry and start
authorisation - R139- , ⇒ General body repairs, interior; Rep.
gr. 68 ; Removing and installing entry mouldings .

Note
The vehicle carpet and the foam section are not shown in the
figure for reasons of clarity.

sive bonding of the interior aerial 2 for entry and start author‐
isation - R139- -1-.
– Remove the interior aerial 2 for entry and start authorisation -
R139- -1- from the vehicle.
Installing:
following:
– Insert connector -3- into interior aerial 2 for entry and start au‐
thorisation - R139- -2- until it engages.
– Push interior aerial 2 for entry and start authorisation - R139-
into foam section -1-.
– Align foam section -1- together with aerial to wiring guide -2-
on centre tunnel.
– Bond interior aerial 2 for entry and start authorisation - R139-
onto centre tunnel.

The entry and start authorisation aerial 3, in interior - R154- is
located under the rear shelf, close to the rear window sun blind.
Note

renewed. Clear the fault entry created in the fault memory via

Removing:
At the time of publication, no information on this subject was
available for this chapter.
14.5.10 Removing and installing luggage com‐

partment aerial for entry and start au‐
thorisation - R137-
The luggage compartment aerial for entry and start authorisation
- R137- is located centrally in the luggage compartment before
the spare wheel recess.
Note
Coding, basic setting and adaption are not necessary if the lug‐
gage compartment aerial for entry and start authorisation - R137-
is renewed. Clear the fault entry created in the fault memory via
Removing:
Note

function.

– Remove luggage compartment floor ⇒ General body repairs,
interior; Rep. gr. 70 ; Removing and installing load and lug‐
gage compartment floor covering, Variant .
sive bonding of the luggage compartment aerial for entry and
start authorisation - R137- -1-.
– Remove the luggage compartment aerial for entry and start
authorisation - R137- -1- from the vehicle.
Installing:

following:
– Before bonding, align aerial on both marks -arrows- on edge
of spare wheel recess.
– Bond luggage compartment aerial for entry and start authori‐
sation - R137- within the marks so that the lower edge of the
aerial housing lies 4-5 mm above the upper edge of the spare
wheel recess.
14.6 Checking entry and start authorisation

aerials and sensors
Following aerials and sensors for entry and start authorisation can
be tested with the vehicle diagnosis tester .
⇒ page 330
R135- ⇒ page 331
♦ Rear bumper aerial for entry and start authorisation - R136-
⇒ page 331
♦ Luggage compartment aerial for entry and start authorisation
- R137- ⇒ page 331
♦ Interior aerial 1 for entry and start authorisation - R138-
⇒ page 331
⇒ page 332
⇒ page 332
⇒ page 332
♦ Front passenger door exterior handle touch sensor - G416-
⇒ page 333
♦ Rear left door exterior door handle touch sensor - G417-
⇒ page 333
♦ Rear right door exterior door handle touch sensor - G418-
⇒ page 333
14.6.1 Checking driver side aerial for entry and

start authorisation - R134-
♦ Body
♦ Convenience system
♦ Entry and start authorisation electrical components

♦ R134 - Driver side aerial for entry and start authorisation
14.6.2 Checking front passenger side aerial for

entry and start authorisation - R135-
♦ Body
♦ R135 - Front passenger side aerial for entry and start author‐
isation
14.6.3 Checking rear bumper aerial for entry

and start authorisation - R136-
♦ Body
♦ R136 - Rear bumper aerial for entry and start authorisation
14.6.4 Checking luggage compartment aerial

♦ Body
♦ R137 - Luggage compartment aerial for entry and start au‐
thorisation
14.6.5 Checking interior aerial 1 for entry and



♦ Body
♦ R138 - Interior aerial 1 for entry and start authorisation

♦ Body

♦ Body
14.6.8 Checking driver door exterior handle

touch sensor - G415-
♦ Body

♦ G415 - Driver door exterior handle touch sensor
14.6.9 Checking front passenger door exterior

handle touch sensor - G416-
♦ Body
♦ G416 - Front passenger door exterior handle touch sensor
14.6.10 Checking rear left door exterior handle

touch sensor - G417-
♦ Body
♦ G417 - Rear left door exterior door handle touch sensor
14.6.11 Checking rear right door exterior door

handle touch sensor - G418-
♦ Body
♦ G418 - Rear right door exterior door handle touch sensor

14.7 Adapting entry and start authorisation

functions
14.7.1 Feedback for unlocking via entry and

start authorisation system
♦ Body
♦ Functions of convenience system central control unit
♦ Adapting feedback for unlocking via entry and start authorisa‐
tion system
14.7.2 Adapting feedback for locking via ac‐

cess and start authorisation system
♦ Body
♦ Adapting feedback for locking via access and start authorisa‐
tion system

15 Specified torques: lights, bulbs,

switches - exterior
15.1 Specified torques: headlights

Top of headlight 2 Nm
Bottom left of headlight 8 Nm
Bottom right of headlight 8 Nm
Guide profile At the time of publication, no information
on this subject was available for this
chapter.
15.2 Specified torques: fog lights

Fog light securing bolts 1.5 Nm
15.3 Specified torques: tail light in side panel (saloon)

Hexagon flange nut 3 Nm
15.4 Specified torques: tail light in side panel (Variant)

Hexagon flange nut 2.5 Nm
Double stud in body 2 Nm
15.5 Specified torques: tail light in rear lid (sa‐

loon)
15.6 Specified torques: tail light in rear lid

(Variant)
15.7 Specified torques: steering column

switch unit
Steering column switch 10 Nm
unit Torx screws to steer‐
ing column
15. Specified torques: lights, bulbs, switches - exterior 335

16 Reversing camera system
Note
♦ When handling complaints, it is essential to understand the

function and operation of the reversing camera system.
♦ Additional information ⇒ Owner's manual
♦ In the event of repair work or fault finding, use ⇒ vehicle di‐
agnosis, testing and information system - VAS 5051A- or
vehicle diagnosis and service information system - VAS 5052-
in “Guided fault finding” mode ⇒ Current flow diagrams, Elec‐
trical fault finding and Fitting locations.
♦ When the battery is reconnected, check operation of electrical
equipment (radio, clock, convenience electronics and so on)
according to the workshop manual and/or the operating man‐
ual.
The reversing camera system supports the driver during revers‐

ing by providing the driver with an image of the traffic situation
behind the vehicle via the radio or radio navigation system dis‐
play. The system is available as an option.
The system is activated when reverse gear is engaged, even if
the radio or radio navigation system is switched off.
The reversing camera system consists of the following compo‐
nents:
♦ Reversing camera - R189-
♦ Reversing camera system control unit - J772-
♦ Control unit with display for radio and navigation - J503-
♦ Steering wheel with steering angle sender - G85-
Note
Installation of an additional number plate carrier is not permissible

on vehicles with reversing camera system as this would impair
the function of the reversing camera. The light of the number plate
could also be impaired.

The reversing camera system is equipped with self-diagnosis.
system - VAS 5051A- or vehicle diagnosis and service information
system - VAS 5052- in “Guided fault finding” mode.
16.2 Assembly overview - reversing camera system

1 - Control unit with display unit

for radio and navigation - J503-
❑ Fitting location: at front
of centre console
⇒ Communication;
Rep. gr. 91
2 - Reversing camera system
❑ Fitting location: in lug‐
gage compartment be‐
hind right side panel trim
⇒ page 340
❑ Coding reversing cam‐
era system control unit
⇒ page 341
3 - Reversing camera - R189-
❑ Fitting location: in han‐
dle button of rear lid
⇒ page 337
❑ Securing nut specified
torque: 6 Nm
❑ Calibrating reversing
camera system
⇒ page 341
4 - Steering angle sender -
G85-
❑ Fitting location: in steer‐
ing column trim behind
steering wheel
⇒ page 282
16.3 Removing and installing reversing cam‐

era
The reversing camera is installed in the handle button of the rear
lid. To remove reversing camera, first remove handle button from
rear lid. Reversing camera can then be removed from handle but‐
ton.
16.3.1 Removing handle button with reversing

camera from rear lid
16. Reversing camera system 337

Removing:
ignition key.
Remove rear lid trim ⇒ General body repairs, interior; Rep. gr.
70 ; Trim/insulation; Rear lid trim .
– Open wire bracket from wiring harness of reversing camera in
connector area and remove both wires.
– Release and disconnect both connectors -arrows-.
– Remove both securing nuts -arrows-.

– Unscrew both securing nuts -arrows- and remove cover from

rear lid, taking connected wiring length into account.
– Release both side locking lugs -arrow- and take handle button
and reversing camera out of cover.
Removing reversing camera out of handle button ⇒ page 339
Installing:
following:
– Secure wiring of reversing camera with wiring retainer to avoid
rattling.
– After installation, clean reversing camera lens with a lint-free
cloth.
– Recalibrate system ⇒ page 341 .
16.3.2 Removing reversing camera out of han‐

dle button
Removing:
– Release locking lugs -arrows- and remove housing -1-.
– Pull reversing camera -1- out of lower part of handle button

-2-.
Installing:

16.4 Reversing camera system control unit
16.4.1 Removing and installing reversing cam‐

era system control unit
Control unit is installed in luggage compartment behind right side
panel trim.
For the Variant, installation is described in the following. For the
saloon, installation steps are similar.
Removing:
ignition key.
– If existing, remove luggage compartment cover and net parti‐
tion.
– Remove lock carrier cover in luggage compartment ⇒ General
body repairs, interior; Rep. gr. 70 ; Trim, insulation; Load and
luggage compartment trims; Removing and installing lock car‐
rier cover .
– Remove both fastening rings -arrows-.
– Unclip side panel trim at points marked with -arrows-.

– When doing this, remove side panel trim from guide in side
window area.
– Carefully squeeze off side panel trim in direction of -arrow-.

– Release and disconnect both connectors -1- and remove con‐

trol unit -arrow- from bracket.
Installing:
Only if control unit has been renewed:
– Recalibrate system ⇒ page 341 .
16.4.2 Coding reversing camera system con‐

trol unit - J772-
– Connect vehicle diagnosis, testing and information system -
VAS 5051A- ⇒ page 409 .
– Select “guided fault finding” in the vehicle diagnosis, testing
and information system - VAS 5051A- .
♦ Body
♦ 01 - On board diagnostic capable system
♦ Reversing camera system
♦ Reversing camera functions
♦ Coding control unit
16.5 Calibrating reversing camera system

Reversing camera system may have to be recalibrated following
repair work on the vehicle. In detail, this is the case after:
♦ Removing and installing reversing camera
♦ Renewing reversing camera system control unit
♦ Accident repairs on rear lid
♦ Suspension height adjustment on one axle of more than 5 mm
♦ Suspension height adjustment of complete vehicle by more
than 10 mm
Extensive preliminary work is required before actual calibration
can be carried out using vehicle diagnosis, testing and information
system - VAS 5051A- or vehicle diagnosis and service information
system - VAS 5052- . This is described in the following.

♦ Calibration unit - VAS 6350-
16.5.1 Preparatory measures for calibration

To carry out calibration, vehicle must be positioned on a firm, level
surface. Nobody may be inside vehicle during measurement. Ve‐
hicle must not be moved during measurement, and opening and
closing vehicle doors is prohibited.
Connect vehicle diagnosis, testing and information system - VAS
5051A- ⇒ page 409 .
– Set steering wheel sender - G85- to 0 position (wheels straight
ahead).
Overview of assembled measuring facility:

1 - Wheel centre mounting -

VAS 6350/1-
2 - Wheel centre mounting -
VAS 6350/1-
3 - Right angle for mounting
measuring unit for distance
measurement
4 - Linear laser - VAS 6350/3-
❑ Switching on and off ⇒
Owner's manual
5 - Plastic foot
❑ Total of three on bottom
of measuring equipment
❑ Adjustable to adjust hor‐
izontal position of meas‐
uring facility
6 - Spacing laser - VAS
6350/2-
❑ Notes on operation ⇒
Owner's manual
7 - Spirit level on measuring fa‐
cility
❑ To check horizontal po‐
sition of measuring fa‐
cility
8 - Left angle for mounting
measuring unit for distance
measurement
9 - Calibration unit - VAS
6350/4-
❑ Distance between angle
brackets of calibration
device
( ⇒ Item 3 (page 343) or ⇒ Item 8 (page 343) ) and paddles on wheel centre mountings of rear wheels:
1.20 m - 1.70 m -dimension A-
– Secure three wheel bolt adapter in each hole circle “112” of

wheel centre mounting.
– Position paddles on both wheel centre mountings and secure
with clamping bolts.

– Insert wheel centre mountings into wheel securing bolts of rear

wheels. Wheel centre mountings are positioned and secured
in the adapters through »O-rings«.
Note
Set wheel centre mountings against wheels so that no »anti-theft

wheel bolts« are connected to wheel bolt adapters.
– Use clamp nuts to adjust paddles so that they move freely just
above the floor.
Make sure the paddles can move freely.
– Position calibration device - VAS 6350/4- behind vehicle at a
distance of 1.20 m - 1.70 m to the angle brackets of the cali‐
bration device and the paddles on the wheel centre mountings,
as shown in the overview diagram -dimension A-
⇒ Item 9 (page 343) .
– Position the calibration device - VAS 6350/4- horizontally. Do

this by turning the plastic feet under the calibration unit until
the air bubble in the spirit level is precisely in the centre of the
indicator -arrow-.
– Switch on laser on calibration unit -1- and align the entire cal‐
ibration unit so that the laser beam -2- contacts the rear end
of the vehicle centrally above the VW badge.
– Switch on the linear laser - VAS 6350/2- for distance meas‐

urement by pressing the ON button. The following display
appears and the laser is activated:

– Hold spacing laser for distance measurement -2- as shown in

illustration flush against bracket on one side of calibration unit
so that spacing laser lies firmly against bracket.
– Ensure that laser beam from spacing laser for distance meas‐
urement hits lower, enlarged part of paddle -1-.
If this is not the case, adjust paddles accordingly on wheel mount‐
ing using clamping bolts.
– Hold distance spacing laser for distance measurement in

bracket on measuring device whilst laser beam is visible on
paddle. Now briefly press the ON button to measure distance.
The following appears in the display:
The distance is shown on the display in “metres”.
– Note the measured value.
– Repeat measuring process in same manner for other rear
wheel on other side of calibration unit.
Measured distance value must be identical on both sides. If value
is not identical, adjust calibration unit until values on both sides
are identical.
When adjusting the calibration unit, ensure that the laser beam of
the spacing laser continues to hit the vehicle centrally above the
VW logo and that the spirit level indicator remains in the centre.
Adjust accordingly if required.
The value for the measured distance must be entered during cal‐
ibration in vehicle diagnosis, testing and information system - VAS
5051A- or vehicle diagnosis and service information system - VAS
5052- in “millimetres”.
Calibrating reversing camera system ⇒ page 345
16.5.2 Calibrating reversing camera system
Note
Note the points regarding preparatory work for calibration

⇒ page 342 .
– Connect vehicle diagnosis, testing and information system -

VAS 5051A- ⇒ page 409 .

– Select “guided fault finding” in the vehicle diagnosis, testing

and information system - VAS 5051A- .
♦ Body
♦ 01 - On board diagnostic capable system
♦ Reversing camera system
♦ Reversing camera functions
♦ Carry out reversing camera calibration
From this point on, you will be guided through the calibration
process by the vehicle diagnosis, testing and information system
- VAS 5051A- or vehicle diagnosis and service information system
- VAS 5052- .
16.6 Renewing video cable

⇒ “16.6.1 Preparation”, page 346
⇒ “16.6.2 Routing repair cable”, page 347
⇒ “16.6.3 Renewing video cable connector strip”, page 347
16.6.1 Preparation
Note
It is not permitted to repair the video cable. The cable may be

renewed only.
The replacement cable can be found in ⇒ ETKA under part num‐

ber “7N1971327”.
– Remove radio ⇒ Rep. gr. 91 ; Radio; Removing and installing
radio .
– Remove glove compartment ⇒ Rep. gr. 68 ; Compartments
and covers; Removing and installing glove compartment .
– Remove lower A-pillar trim ⇒ Rep. gr. 70 ; Trim; Assembly
overview - A-pillar trim .
– Remove front and rear sill panel mouldings ⇒ Rep. gr. 70 ;
Trim; Removing and installing sill panel moulding .
– Remove lower B-pillar trim ⇒ Rep. gr. 70 ; Trim; Assembly
overview - B-pillar trim .
– Remove right side panel trim in luggage compartment ⇒ Rep.
gr. 70 ; Luggage compartment trims; Removing and installing
side panel trim in luggage compartment .

16.6.2 Routing repair cable

Video cable routing
Note
It is not permitted to repair the video cable. The cable may be

renewed only.
Caution
When routing the cable, ensure that it is not kinked and that it
does not rub anywhere.
– Switch off ignition.

– Position 26-pin connector of repair cable near radio.
Note
Ensure that the cable is sufficiently long to permit later installation

and removal of the radio.
– Guide repair cable directly from radio slot towards glove com‐
partment.
– Secure cable to dash panel cross member using cable ties.
– Secure cable to upper A-pillar using cable ties.
– Guide through lower section of A-pillar.
– Route cable parallel to main wiring harness and fix it in place.
Caution
When routing the cable, ensure that it is not kinked and that it
does not rub anywhere.
16.6.3 Renewing video cable connector strip

– Separate old 54-pin connector from reversing camera system
– Open old 54-pin connector and remove video cable.
– Open new 54-pin connector and remove video cable connec‐
tor strip.
– Insert new video cable connector strip in old connector and
assemble connector housing.
– Connect connector to reversing camera system control unit -
J772- .
– Coil excess length of cable and secure to main wiring harness.
– Shorten defective video cable and wrap it in main wiring har‐
ness.
– Test functionality.
– Read fault memory and clear it.

96 – Lights, bulbs, switches - interior

1 Interior lights and switches
1.1 Removing and installing interior moni‐

toring deactivation switch - E267- and
deactivation button for vehicle inclina‐
tion sender - E360-
♦ Removal wedge - 3409-
Note

♦ The anti-theft alarm system must be deactivated before re‐
moving the interior monitor deactivation switch - E267- and the
deactivation button for vehicle inclination sender - E360- .
♦ The interior monitor deactivation switch - E267- and the de‐
activation button for vehicle inclination sender - E360- form
one component.
♦ The interior monitor deactivation switch - E267- and the de‐
activation button for vehicle inclination sender - E360- are
located in the B-pillar trim on the driver side.
The following components are integrated in the interior monitor

deactivation switch - E267- :
♦ Interior monitoring off warning lamp - K162-
♦ Deactivation of interior monitoring system switch illumination
bulb - L118-
The following components are integrated in the deactivation but‐
ton for vehicle inclination sender - E360- :
♦ Interior monitoring off warning lamp - K162-
The interior monitoring off warning lamp - K162- and the vehicle
inclination sender warning lamp - K188- can be checked by the
unit - J393- ⇒ page 434 .
348 Rep. gr.96 - Lights, bulbs, switches - interior

Removing:
– Carefully lever out interior monitor deactivation switch - E267-
and deactivation button for vehicle inclination sender - E360-
using removal wedge - VAS 3409- or a suitable screwdriver.

Installing:
1.2 Footwell lights

Footwell lights:
♦ Left footwell light - W9-
♦ Right footwell light - W10-
Note
The footwell lights are located in the trim below the dash panel.
1.2.1 Removing and installing footwell lights

1. Interior lights and switches 349

Note

♦ The footwell lights are located in the trim below the dash panel.
♦ Removal and installation of all footwell lights are performed in
the same manner and are described only for one light.
Removing:
– Use removal wedge - 3409- or a suitable screwdriver to care‐
fully prise out footwell light.
– Release connection and pull it off.
Renewing bulb:
– Release locking lugs -1- and remove heat shield -2- from lens
of footwell light.
– Carefully lever bulb out of holder.

– Renew glass-base bulb (12 V, 5 W).
Installing:
1.2.2 Checking footwell lights

The footwell lights ( left footwell light - W9- and right footwell light
- W10- ) can be checked by the final control diagnosis for the

2 Lights and switches in engine com‐

partment
2.1 Removing and installing bonnet contact

switch - F266-
Removing:
– Remove bonnet lock ⇒ General body repairs, exterior; Rep.
gr. 55 ; Bonnet; Removing and installing bonnet lock; Remov‐
ing .
– Release connector -2- and pull it off.
– Unclip cable retainer -1-.
– Cut-off cable tie -2-.

– Release locking lug -1- and move bonnet contact switch -
F266- in elongated holes until it can be removed.
Installing:
2. Lights and switches in engine compartment 351

3 Lights and switches in dash panel
3.1 Removing and installing light switch -

E1-
The following components are integrated into the light switch -
E1- :
♦ Fog light switch - E7-
♦ Rear fog light switch - E18-
♦ Bulb for illumination of light switch - L9-
Removing:
– Turn rotary grip of light switch to position “0”.
– Push in rotary grip of light switch -arrow 1- and turn it clockwise
slightly -arrow 2-.
– Hold rotary grip in this position and pull light switch - E1- at
rotary grip out of dash panel -arrow 3-.
– Release connector -arrow- and pull connector off light switch

- E1- .
Installing:
– Reconnect connector to light switch - E1- .
Note
The connector is not shown in the figure for reasons of clarity.
– Hold light switch - E1- tight and push rotary grip into light switch
-1- and simultaneously turn it clockwise -2-.
– Hold rotary grip in this position and insert light switch - E1- into
dash panel -3- using rotary grip.
– Turn rotary grip to “0” position, release and engage switch.


control regulator - E102- and switch and
instrument illumination regulator - E20-
Note
The headlight range control regulator - E102- and the switch and
instrument illumination regulator - E20- form a single component.
Removing:
– Push regulator -1- out of dash panel by pressing on back of
regulator.
– Unclip connector -arrow- and disconnect.

Installing:
3.3 Removing and installing electrome‐

chanical parking brake button - E538-
The following components are integrated into the electromechan‐
ical parking brake button - E538- :
♦ Electromechanical parking brake warning lamp - K213-
♦ Auto-hold warning lamp 2 - K238-
3. Lights and switches in dash panel 353

Note
When removing and installing components that are in view

(switches, covers, trim and so on), mask off areas in which tools
( removal wedge - 3409- , screwdriver) are used to lever out those
components using commercially available tape.
Removing:
– Remove side cover -1- of dash panel by inserting removal
wedge - 3409- or a suitable screwdriver in recess -2- and lev‐
ering off side cover -1- in direction of -arrow-.
– Push electric parking brake operating unit - E538- -1- out of

dash panel by pushing on back of operating unit.


Installing:
3.4 Removing and installing front passenger

side airbag deactivated warning lamp -
K145-
WARNING
Observe safety precautions when working on airbag ⇒ Gen‐

eral body repairs, interior; Rep. gr. 69 ; Airbag; Safety pre‐
cautions when working on airbag .

Note

Removing:

– Carefully lever off trim -1- on locking lugs -arrows- using re‐
moval wedge - VAS 3409- .

– Release front passenger side airbag deactivated warning
lamp - K145- -arrow- and remove it from the trim.
Installing:
3.5 Removing and installing glove compart‐

ment light - W6-
Note

Removing:

– Carefully lever out glove compartment light - W6- out with re‐
moval wedge - 3409- or a suitable screwdriver.
– Release connector and remove the plug.
Renewing bulb:
– Release locking lugs -1- and remove heat shield -2- from lens
of glove compartment light - W6- .
– Carefully lever bulb out of holder.

Installing:

3.6 Removing and installing glove compart‐

ment light switch - E26-
Note
♦ The illustration shows the glove compartment light switch -

E26- -1- with the dash panel removed. There is no requirement
to remove the dash panel in order to remove the switch.
♦ The glove compartment light switch - E26- -1- is accessible
when the glove compartment is open, whereupon it can be
unclipped.
Removing:
– Unclip glove compartment light switch - E26- -1- with wiring
still connected -arrows-.
– Pull glove compartment light switch - E26- out as far as wiring
allows and separate connection.
Installing:
3.7 Removing and installing hazard warning

light switch - E3-
The following components are integrated into the hazard warning
light switch - E3- :
♦ Indicator lamp for hazard warning light - K6-
Note

♦ Remove trims only in the sequence described.
Removing:

– Remove trim -2- using removal wedge - 3409- ⇒ General body

repairs, interior; Rep. gr. 68 ; Compartments, covers and trim;
Removing and installing trim in centre of dash panel .
Trim; Removing and installing dash panel insert .
Removing and installing trim on front passenger side of dash
panel .
Removing and installing trim for Infotainment .
Carrier, Removing and installing blind cover .
– Unscrew securing screws -arrows- and remove retainer -1-

with hazard warning light switch - E3- .
– Release locking lugs -arrows- and remove hazard warning

light switch - E3- -1-.
Installing:

4 Lights and switches in front doors
4.1 Removing and installing driver side

switch element
The following components (depending on level of equipment) are
integrated into the driver side switch element:
♦ Front left window regulator switch - E40-
♦ Rear left window regulator switch, in driver door - E53-
♦ Rear right window regulator switch, in driver door - E55-
♦ Front right window regulator switch, in driver door - E81-
♦ Childproof lock button - E318-
Note

Removing:
– Carefully lever off trim using removal wedge - 3409- on locking
lugs -arrows-.

– Release locking lugs -arrows- and remove switch element

-1- from handle trim.
Installing:
4.2 Removing and installing driver side in‐

terior locking button for central locking
system - E308-
The following components are integrated in the driver side interior
locking button for central locking system - E308- :
♦ Driver side interior locking warning lamp - K174-
Removing:
– Remove door trim ⇒ General body repairs, interior; Rep. gr.
70 ; Door trim; Removing and installing driver side front door
trim; Removing .
– Release connector -1-, pull off connector and remove screw
-arrow-.
4. Lights and switches in front doors 361

– Release locking lugs -arrows- and remove door opener along

with driver side interior locking button for central locking sys‐
tem - E308- .
– Release locking lugs -arrows- and remove driver side interior

locking button for central locking system - E308- -1-.
Installing:
4.3 Removing and installing mirror adjust‐

ment switch - E43-
integrated into the mirror adjustment switch - E43- :
♦ Mirror adjustment changeover switch - E48-
♦ Exterior mirror heater button - E231-
♦ Fold-in mirror switch - E263-
♦ Mirror adjustment switch illumination bulb - L78-
Note

( removal wedge - 3409- , screwdriver) are used to prise out those
components using commercially available masking tape.

Removing:
– Carefully lever off trim using removal wedge - 3409- on locking
lugs -arrows-.
– Release locking lugs -arrows- and remove mirror adjustment

switch - E43- -1- from handle trim.
Installing:
4.4 Removing and installing remote release

button for fuel filler flap and rear lid -
E233-
Removing:
trim; Removing .
– Unclip connector -1- and disconnect.

– Release locking lugs -arrows- and remove remote release

button for fuel filler flap and rear lid - E463- -2- from door trim
panel.
Installing:
4.5 Removing and installing key-operated

switch to block release of rear lid remote
- E232-
Removing:
trim; Removing .
– Release locking lugs -arrows- and remove key-operated

switch to block release of rear lid remote - E232- -1- from door
trim panel.
Installing:

4.6 Removing and installing central locking

SAFELOCK function warning lamp -
K133-
4.6.1 Removing and installing central locking

SAFELOCK function warning lamp -
K133-
Removing:
trim; Removing .
– Unclip central locking SAFELOCK function warning lamp -
K133- -1- by pressing locking lugs together -arrows- and re‐
move from door trim panel.
– Pull connector -1- off central locking SAFELOCK function

warning lamp - K133- -2-.
Installing:
4.6.2 Checking central locking SAFELOCK

function warning lamp - K133-
The central locking SAFELOCK function warning lamp - K133-
can be checked by the final control diagnosis for the driver door
control unit - J386- ⇒ page 437 .

4.7 Removing and installing window regula‐

tor switch in front passenger door -
E107-
Note
The window regulator switch in front passenger door - E107- con‐

tains an integral window regulator switch illumination bulb - L53- ,
which cannot be renewed separately.
Removing:
70 ; Door trim; Removing and installing front passenger side
front door trim; Removing.
– Remove securing screws -arrows- and remove handle along
with window regulator switch in front passenger door - E107- .
– Release locking lugs -arrows- and remove window regulator

switch -1-.
Installing:
4.8 Front left entry light - W31- and front

right entry light - W32-
Note
Removal and installation of all entry lights are performed in the

same manner and are described only for one light.
Entry lights:
♦ Front left entry light - W31-
♦ Front right entry light - W32-

♦ Rear left entry light - W33-

♦ Rear right entry light - W34-
4.8.1 Removing and installing front entry

lights -W31- and -W32-
Note

♦ Removal and installation of all entry lights are performed in the
same manner and are described only for one light.
Removing:
– Use the removal wedge - 3409- or a suitable screwdriver to
carefully prise out the light.
– Release connector and remove the plug.
Renewing bulb:
– Carefully prise lens off housing.

– Carefully pull bulb -1- out of holder.

Installing:
4.8.2 Checking front entry lights -W31- and -

W32-
The front left entry light - W31- can be checked by the final control
diagnosis for the driver side door control unit - J386-
⇒ page 437 .
The front right entry light - W32- can be checked using final control
diagnosis for the front passenger side door control unit - J387-
⇒ page 438 .
4.9 Components - front door locks

integrated into the driver side door lock:
♦ Driver door contact switch - F2-
♦ Driver side central locking switch - F59-
♦ Driver side central locking lock unit - F220-
♦ Driver door central locking motor - V56-
♦ Driver door central locking SAFELOCK function motor - V161-
integrated into the passenger side door lock:
♦ Front passenger door contact switch - F3-
♦ Front passenger side central locking lock unit - F221-
♦ Front passenger side central locking motor - V57-
♦ Front passenger door central locking SAFELOCK function
motor - V162-
Note
♦ The above mentioned components cannot be renewed indi‐

vidually.
♦ All the components in the driver side door lock can be checked
by the final control diagnosis for the driver door control unit -
J386- ⇒ page 437 .
♦ All the components in the front passenger side door lock can
be checked by the final control diagnosis for the front passen‐
ger door control unit - J387- ⇒ page 438 .
In the event of component defects - front door locks:

– Replace corresponding door lock ⇒ General body repairs,
exterior; Rep. gr. 57 ; Front door; Door components; Central
locking; Removing and installing door lock.

5 Lights and switches in rear doors
5.1 Removing and installing rear window

regulator switch -E52- and -E54-
Note
♦ The procedure for removal and installation of the rear left win‐
dow regulator switch, in door - E52- and the rear right window
regulator switch, in door - E54- is the same and is therefore
described for one switch only.
♦ The rear left window regulator switch, in door - E52- contains
an integral window regulator switch illumination bulb - L53- ,
♦ The rear right window regulator switch, in door - E54- contains
an integral window regulator switch illumination bulb - L53- ,
Removing:
70 ; Door trim; Removing and installing rear door trim; Re‐
moving.
– Remove securing screws -arrows- and remove handle along
with window regulator switch.
– Release locking lugs -arrows- and remove window regulator

switch -1-.
Installing:
5. Lights and switches in rear doors 369

5.2 Rear left entry light - W33- and rear right

entry light - W34-
5.2.1 Removing and installing rear entry lights

-W33- and -W34-
Note
Removal and installation of all entry lights are performed in the

same way and are described only for one light ⇒ page 367 .
5.2.2 Checking rear entry lights -W33- and -

W34-
Rear left entry light - W33- and rear right entry light - W34- Can
be checked using final control diagnosis for convenience system
central control unit - J393- ⇒ page 434 .
5.3 Components - rear door locks

integrated into the rear left door lock:
♦ Rear left door contact switch - F10-
♦ Rear left central locking lock unit - F222-
♦ Rear left door central locking SAFELOCK function motor -
V163-
♦ Rear left door central locking motor, lock - V214-
integrated into the rear right door lock:
♦ Rear right door contact switch - F11-
♦ Rear right central locking lock unit - F223-
♦ Rear right door central SAFELOCK function locking motor -
V164-
♦ Rear right door central locking motor, lock - V215-
Note

vidually.
♦ The rear left central locking lock unit - F222- and the rear right
central locking lock unit - F223- . Can be checked using final
control diagnosis for convenience system central control unit
- J393- ⇒ page 434 .
In the event of component defects - rear door locks:

– Replace corresponding door lock ⇒ General body repairs,
exterior; Rep. gr. 58 ; Rear door; Door components, Removing
and installing door lock.

6 Lights and switches in luggage com‐

partment
6.1 Luggage compartment light - W3-
6.1.1 Removing and installing luggage com‐

partment light - W3-
Removing:
– Carefully prise luggage compartment light - W3- out with re‐
moval wedge - 3409- or a suitable screwdriver.

Renewing bulb:
6. Lights and switches in luggage compartment 371

– Press contact plate -1- of luggage compartment light - W3- in

direction of -arrow- and remove bulb -2- from holder.
– Renew festoon bulb (12 V, 10 W).
Installing:
6.2 Rear lid lock unit - F256-

The following components are integrated into the rear lid lock unit
- F256- :
♦ Luggage compartment light switch - F5-
♦ Rear lid electric release motor - V254-
Note

vidually.
♦ The rear lid lock unit - F256- can be checked using final control
diagnosis for convenience system central control unit - J393-
⇒ page 434 .
6.2.1 Removing and installing rear lid locking

unit - F256-
The rear lid locking unit - F256- is integrated into the rear lid lock
and cannot be renewed individually.
If the rear lid locking unit - F256- is found to be defective, the entire
rear lid lock must always be renewed.
– Replace rear lid lock ⇒ General body repairs, exterior; Rep.
gr. 55 ; Covers and flaps; Rear lid; Assembly overview - lock‐
ing and unlocking components.

7 Lights and switches in roof trim
7.1 Front interior light

integrated into the front interior light:
♦ Front interior light button - E326-
♦ Driver side reading light button - E457-
♦ Front passenger side reading light button - E458-
♦ Front interior light - W1-
♦ Left centre reading light - W39-
♦ Right centre reading light - W40-
♦ Sunroof switch - E8-
♦ Sliding sunroof switch illumination bulb - L65-
♦ Telephone microphone - R38-
7.1.1 Removing and installing front interior

light
Note

Removing:
7. Lights and switches in roof trim 373

– Carefully lever out trim -1-.
– Remove screws -1-, release locking lugs -arrows B- and re‐

move interior light from moulded headliner, as far as wiring
allows in direction of -arrow A-.
– Release connectors -1- and -2- and disconnect them.

– Unclip telephone microphone - R38- -arrow- on vehicles with
a hands-free system.
– Remove front interior light.
Installing:
7.1.2 Renewing front interior light - W1-

Removing:
– Remove front interior light ⇒ page 373 .
– Press contact plate -1- of front interior light - W1- in
-direction of arrow- and remove festoon bulb -2-, together with
contact plate, from holder.
– Renew festoon bulb (12 V, 10 W).
Installing:

7.1.3 Replacing front reading lights -W13- and

-W19-
Note
The renewal of the bulbs is the same for both reading lamps.
Removing:
– Turn bulb holder in direction of -arrow- and remove.
– Carefully pull bulb out of holder.

Installing:
7.1.4 Removing and installing front interior

light button - E326- , front interior light
button -E457- and -E458-
Note
♦ The front interior light button - E326- , driver side reading light
button - E457- and front passenger side reading light button -
E458- cannot be replaced individually.
♦ The complete component must be renewed in the event of re‐
pair.

7.1.5 Removing and installing sliding sunroof

switch - E8-
Note
The sliding sunroof switch illumination bulb - L65- is located in the

sunroof switch - E8- .
Removing:
– Disconnect connector -arrow-.
– Release locking lugs -arrows- and remove sunroof switch - E8-

from trim.
Installing:
7.2 Rear interior and reading lights

The following components are integrated into the rear interior light
and reading light:
♦ Rear left reading light - W11-
♦ Rear right reading light - W12-
♦ Rear interior light - W43-
Note
♦ The removal and installation of all lamps is identical

⇒ page 378 .
♦ The interior light and reading light and the switches for the
interior light and reading light are permanently connected. In
the event of repair, the complete component must be renewed.

7.2.1 Removing and installing rear interior

and reading lights
Note

Removing:
– Switch off ignition and all electrical consumers.
– Release locking lugs -arrows- and remove trim with lens from
interior light and reading lamp.
– Release locking lugs -arrows- and remove interior light and

reading lamp out of moulded headliner.


Installing:
7.2.2 Renewing rear interior and reading light

bulbs
Removing:
– Release locking lugs -arrows- and remove trim with lens from
interior light and reading lamp.
– Carefully pull glass-base bulb out of holder -arrows-.

– Renew defective glass-base bulb (12 V, 5 W).
Installing:
7.3 Illuminated vanity mirrors -W20- and -

W14- with contact switches for vanity
mirrors -F147- and -F148-
The vanity mirror contact switch and vanity mirror light are inte‐
grated in the sun visor and cannot be renewed individually.
If the vanity mirror contact switch or the light is defective, the
complete sun visor must always be renewed.
– Renewing basic sun visor ⇒ General body repairs, interior;
installing basic sun visor .
– Renewing double sun visor ⇒ General body repairs, interior;
installing double sun visor .

7.4 Garage door opener

The garage door opener is integrated in the sun visor on the driver
side. The garage door opener control unit - J530- , button 1 for
garage door opener - E392- , button 2 for garage door opener -
E393- , button 3 for garage door opener - E394- and garage door
opener warning lamp - K179- are integrated into one unit in the
sun visor.
7.4.1 Removing and installing garage door

opener
Note
♦ The garage door opener cannot be renewed individually. The

complete sun visor must be renewed when defective.
♦ ⇒ Operating manual
Removing:
– Remove driver side sun visor ⇒ General body repairs, interior;
installing basic sun visor or ⇒ General body repairs, interior;
installing double sun visor .
7.5 Automatic anti-dazzle interior mirror -

Y7-
7.5.1 Removing and installing automatic anti-

dazzle interior mirror - Y7-
– Remove the interior mirror ⇒ General body repairs, interior;
Rep. gr. 68 ; Removing and installing interior mirror.

8 Lights and switches in centre console
8.1 Removing and installing switches in

centre console
The procedure for removal and installation of the following com‐
ponents is identical and is therefore described for one component
only.
♦ Rear roller blind switch - E149-
♦ TCS and ESP button - E256-
♦ Parking aid button - E266-
♦ Park assist steering button - E581-
♦ Tyre pressure monitor display button - E492-
♦ Auto-hold button - E540-
Note

Removing:
– Disconnect connector.
– Release locking lug arrow and remove switch.
Installing:

8.2 Removing and installing front ashtray il‐

lumination bulb
The function of the illumination of the front ashtray is undertaken
by the cigarette lighter illumination bulb - L28- . It is a component
of the cigarette lighter - U1- and can only be removed and installed
together with the cigarette lighter - U1- .
– Removing and installing cigarette lighter - U1- ⇒ page 381
8.3 Removing and installing cigarette lighter

- U1-
The cigarette lighter - U1- is located in the front section of the
centre console next to the ashtray.
Removing:
8.4 Removing and installing heated rear

seat switches -E128- and -E129- with
regulator
The procedure for removal and installation of the heated rear left
seat switch with regulator - E128- and the heated rear right seat
switch with regulator - E129- is the same and is therefore descri‐
bed for one switch only.
Note

Removing:
8. Lights and switches in centre console 381

– Remove bolts -arrows-.
– First pull trim backwards in direction of -arrow 1-, then upwards

in direction of -arrow 2- and remove trim.
– Release connector -1- and disconnect it.

– Remove heated rear left seat switch with regulator - E128-
-2- from trim.
Installing:
8.5 Removing and installing storage com‐

partment illumination bulb - L120-

Note

Removing:


– Unclip connector -2-, release it and pull it off connector.

– Unclip storage compartment illumination bulb - L120- -1- and
pull it out along with the wiring.
Installing:
8.6 Removing and installing AC/DC con‐

verter with socket, 12 V - 230 V - U13-
WARNING
♦ Capacitors are also located in the housing of the AC/DC

converter with socket, 12 V - 230 V - U13- and these are
charged with a residual voltage.
♦ There is a danger of an electric shock.
♦ The housing of the AC/DC converter with socket, 12 V -
230 V - U13- must never be opened.


Note

♦ The connector, wiring and 230 V socket must never be re‐
paired.
♦ The complete unit must be replaced if the connector, wiring,
230 V socket or the AC/DC converter are defective.
Removing:



– Unclip heated rear seat switch with regulator from trim on ve‐
hicles with heated rear seats.
– Release socket at locking lugs -arrows- and pull it out.

Installing:

9 Horn
9.1 Removing and installing treble horn -

H2- and bass horn - H7-
Note
♦ The treble horn - H2- and the bass horn - H7- are actuated in
parallel by the onboard supply control unit - J519- .
♦ The procedure for removal and installation of both horns is the
same and is therefore described for just one horn.
♦ The treble horn - H2- and the bass horn - H7- are fitted on the
left/right of the radiator respectively.
Removing:
– Switch off ignition and all electrical consumers.
– Remove securing bolt -1- and remove horn -3- with bracket.
Installing:
– Install in the reverse order of removal. When doing this, note
the following:
– Tighten threaded connections to specified torque
⇒ page 408 .
9.2 Checking treble horn - H2- and bass

horn - H7-
The horns ( treble horn - H2- and bass horn - H7- ) can be checked
in final control diagnosis for the onboard supply control unit -
J519- ⇒ page 424 .
9.3 Horn plate - H-

The horn is operated via the spring mounted cover in the centre
of the steering wheel. Depending on equipment, the horn plate is
either a component part of the steering wheel or integrated into
the airbag unit on the driver side and cannot be replaced as an
individual item. If horn plate is defective, renew driver side airbag
unit or steering wheel.
Remove driver airbag unit ⇒ General body repairs, interior; Rep.
gr. 69 ; Airbag; Removing and installing driver airbag unit .
Remove steering wheel ⇒ Running gear; Rep. gr. 48 ; Assembly
overview - steering wheel; Removing and installing steering
wheel .
9.3.1 Checking horn plate

9. Horn 387

♦ Body
♦ Horn plate -H-

10 Immobiliser
Note

System
The Passat features a fourth-generation immobiliser with online
connection. The main component of the fourth generation immo‐
bilizer is a central database, in which all of the theft-relevant data
from the participating control units is stored. Adapting the control
units associated with the immobiliser is not possible without an
online link to this database.
Online system test ⇒ page 396
New features of the forth-generation immobiliser:
♦ A PIN request for the immobiliser components via fax or tem‐
porary access authorisation to the components is not availa‐
ble.
♦ All components associated with the immobilizer must be adap‐
ted online.
♦ All – including re-ordered – ignition keys are pre-coded to a
specific vehicle in the factory and can only be adapted to this
vehicle.
♦ The relevant vehicle identification number must be specified
when re-ordering ignition keys.
♦ It is no longer possible to adapt components of other brands
for use in Volkswagen vehicles.
Immobilizer components:
♦ Immobiliser control unit - J362- ⇒ page 390
♦ Electronic steering column lock (ESL) control unit - J764-
⇒ page 392
♦ Electronic ignition lock - D9- ⇒ page 390
♦ Engine control unit - J623- ⇒ Rep. gr. 24 ; Engine control unit
♦ Ignition key ⇒ page 394
Changing all components for immobiliser ⇒ page 396
Immobiliser control unit - J362- functions:
♦ Storing all theft-relevant data in the central database via the
online link.
♦ Communication between all components associated with the
immobiliser.
♦ Encryption of data between associated control units.
The immobiliser is equipped with self-diagnosis, which makes
fault finding easier.
10. Immobiliser 389


10.1 Immobiliser control unit - J362-

The immobiliser control unit - J362- is integrated in the conven‐
ience system central control unit - J393- .
If the immobiliser control unit is defective, the convenience sys‐
tem central control unit - J393- must be renewed.
– Removing and installing convenience system central control
unit - J393- ⇒ page 432 .
Note
equipment.
10.1.1 Adapting immobiliser control unit - J362-

J393- , the immobiliser must be adapted.
♦ Body
♦ Immobiliser
♦ Immobiliser functions
♦ Adaption when changing immobiliser
10.2 Immobiliser reader unit - D1-

The immobiliser reading unit - D1- is integrated in the electronic
ignition switch and cannot be replaced separately.
Electronic ignition lock - D9- : ⇒ page 390
10.3 Electronic ignition lock - D9-

The following components (depending on equipment) are inte‐
grated into the electronic ignition lock:

♦ Ignition key withdrawal lock solenoid - N376- (vehicles with

automatic gearbox only)

tion lock - D9-
Note
If electronic ignition lock - D9- is renewed, no coding, basic setting

or adaption are necessary.

♦ Pliers - VAS 6339-
Removing:
– Remove trim on driver side ⇒ General body repairs, interior;
installing trim on driver side .
– Press cover -3- of trim -1- downwards to gain access to the
fasteners of the trim -1-.
– Press fasteners of trim -1- outwards through recesses -2- on

both sides using pliers - VAS 6339- .
– Remove trim.
10. Immobiliser 391

– Remove bolt -1-.
– Release fasteners -arrow- on both sides and remove elec‐

tronic ignition lock - D9- -2- from trim on driver side -1- in
direction of -arrow-.
Installing:
Note
Ensure fasteners of electronic ignition lock have locked correctly

into trim on driver side when installing.
10.3.2 Checking electronic ignition lock - D9-

♦ Body
♦ Immobiliser
♦ Immobiliser electrical components
♦ D9 electronic ignition lock
10.4 Electronic steering column lock (ESL)

Steering column lock control element - J764- is integrated into
electronic steering column lock control unit - N360- .
Steering column locking and unlocking are released via immobil‐
iser control unit - J362- in convenience system central control unit
- J393- .
10.4.1 Removing and installing electronic

steering column lock control unit - J764-
Removing:
♦ T10424

Note
♦ The Steering column lock control element - J764- is secured

to steering column with shear bolts.
♦ All information on further procedure can be obtained via vehi‐
cle diagnosis tester .
♦ If the electronic steering column lock control unit - J764- is to
be renewed, the procedure for “adapting the electronic steer‐
ing column lock control unit” must always be carried out after‐
wards ⇒ page 394 .
– Removing steering column with electronic steering column

lock control unit - J764- ⇒ Running gear, axles, steering; Rep.
gr. 48 .
– Carefully fit the steering column with protective elements in
vice -1- and move the universal joint -2- down.
– Remove lower shear-head bolt from electronic steering col‐
umn lock control unit - J764- using special tool T10424.
Note
Remove the chips with a brush. Damage could otherwise occur.
– Release vice and turn steering column through 180°.

– Tighten vice and move universal joint -2- down.
– Remove lower shear-head bolt -arrow- from electronic steer‐

ing column lock control unit - J764- using special tool T10424.
Note
♦ Remove the chips with a brush. Damage could otherwise oc‐

cur.
♦ It is necessary to turn through 180° to prevent chips from en‐
tering the steering column from above upon loosening the
shear-head bolt.
Installing:
– Secure electronic steering column lock control unit - J764-

-4- using new shear-head bolts -arrows-. Tighten shear-head
bolts evenly until bolt head breaks off.
– Switch on the ignition and adjust the electronic steering lock
control unit - J764- ⇒ Vehicle diagnostic tester, ⇒ page 394
– Switch off the ignition and install steering column with elec‐
tronic steering column lock control unit - J764- ⇒ Running
gear, axles, steering; Rep. gr. 48 .
10. Immobiliser 393

10.4.2 Adapting electronic steering column

lock control unit - J764-
Note
Do not switch off the ignition whilst adjusting-

♦ Body
♦ Immobiliser
♦ Adapting electric steering column lock
10.4.3 Checking electronic steering column

♦ Body
♦ Immobiliser
♦ J764 Electronic steering column lock control unit
10.5 Ignition key

The ignition key is designed without a key bit, as, for the first time,
the vehicle is started via a pushing motion not with a turning mo‐
tion. The reading coil for identifying the key and an emergency
key are integrated into the ignition key. The emergency key
serves to mechanically unlock the driver door when opening via
radio remote control is not possible. The emergency key is inser‐
ted into the ignition key and can be disengaged in two stages by
pressing the button on the side.
Detent 1 = emergency key is fully inserted
Detent 2 = key fob can be used - emergency key remains locked
The various terminal voltages (term. S, term. 15) and the starting
process are switched on by pushing the start button in the elec‐
tronic ignition lock - D9- . The following switch positions are
possible via pushing the start button:
♦ P0 - off (pre-detent)
♦ P1 - S contact on

♦ P3 - terminal 15 drive (after the starting process, the ignition

key automatically springs back to this position)
In vehicles equipped with Kessy (Keyless Entry Start Stop Sys‐
tem), the switching processes in the ignition lock are carried out
with a start button. This start button remains in the ignition lock
and only functions together with a valid ID sender in the radio
remote control ignition key. Further information on the KESSY
system ⇒ page 319
10.5.1 Loss of the ignition key
Note
Before removing lock set or control units,“"New identity on re‐

newing all components"” function
⇒ “10.5.4 New identity on renewing all components”, page 396
must be called up.
All – including re-ordered – ignition keys are pre-coded to a spe‐

cific vehicle in the factory and can only be adapted to this vehicle.
The relevant vehicle identification number must be specified
when re-ordering ignition keys. The new keys must subsequently
be adapted to the convenience system central control unit -
J393- .
Note
♦ If the entire lock set (all keys and lock cylinders) is renewed,
the electronic steering column lock control unit - J764- must
also be renewed together with the convenience system central
♦ Before removing lock set or control units, “New identity on re‐
newing all components” function must be called up
⇒ page 396 .
Adapting ignition key to convenience system central control unit

- J393- ⇒ page 395 .
Checking ignition key ⇒ page 396
10.5.2 Adapting ignition keys

Adapting ignition key to convenience system central control unit
- J393- :
♦ Body
♦ Immobiliser
♦ Adapting ignition keys
10. Immobiliser 395

10.5.3 Checking ignition key

♦ Body
♦ Immobiliser
♦ Ignition key
10.5.4 New identity on renewing all compo‐

nents
This program performs all the processes required for a recon‐
struction/reinitialisation of all immobiliser components.
♦ Body
♦ Immobiliser
♦ New identity on renewing all components
10.6 Online system test

The following processes are performed with this test program:
♦ System test for online connection
♦ Check of user authorization
♦ Test for correct line connection to Volkswagen database
Prerequisite for this is the online connection (network connection)
of the tester.
♦ Body
♦ Immobiliser
♦ Online system test

11 Anti-theft alarm (ATA)
Note
System
The functions of the ATA are integrated into the convenience
J393- , the anti-theft alarm must be adapted ⇒ page 430 .
Note
equipment.

The anti-theft alarm has a self-diagnosis function, which makes
fault finding easier.
Note
♦ If the anti-theft alarm has been triggered, the alarm source

stored in the convenience system central control unit - J393-
can be read ⇒ page 435 .
♦ Once the alarm horn - H12- has been triggered the source of
the alarm, which has been stored in the convenience system
central control unit - J393- can be read ⇒ page 435 .
11. Anti-theft alarm (ATA) 397

11.1 Assembly overview - anti-theft alarm

(ATA)
Note
The components of the anti-theft alarm (ATA) is dependent on the

vehicle equipment.
1 - Contact switch for bonnet -

F266-
❑ In lid lock
⇒ page 351
2 - Alarm horn - H12-
❑ In front right wheel
housing
⇒ page 403
3 - Convenience system cen‐
tral control unit - J393-
❑ Behind glove compart‐
ment
⇒ page 432
4 - Front passenger door con‐
trol unit - J387-
❑ In front passenger door
⇒ Glazing, window reg‐
ulator; Rep. gr. 64 ; Re‐
moving and installing
window regulator motor
5 - Front passenger door con‐
tact switch - F3-
❑ In front passenger side
central locking lock unit
- F221-
⇒ General body repairs,
exterior; Rep. gr. 57 ;
Front door, door compo‐
nents, central locking;
Removing and installing front door lock
6 - Interior monitor send and receive module 1 - G303- with interior monitor sensors and vehicle inclination
sender - G384-
❑ In the roof console
7 - Rear right door contact switch - F11-
❑ In rear right central locking lock unit - F223-
❑ Removing and installing ⇒ General body repairs, exterior; Rep. gr. 58 ; Rear door, door components;
Removing and installing door lock
8 - Rear lid lock unit - F256-
❑ Removing and installing ⇒ General body repairs, exterior; Rep. gr. 55 ; Covers, flaps, rear lid; Assembly
overview - locking and unlocking components

9 - Rear left door contact switch - F10-

❑ In rear left central locking lock unit - F222-
❑ Removing and installing ⇒ General body repairs, exterior; Rep. gr. 58 ; Rear door, door components;
Removing and installing door lock
10 - Interior monitor deactivation switch - E267- and deactivation button for vehicle inclination sender - E360-
❑ In trim of B-pillar on driver side
11 - Driver door contact switch - F2-
❑ In driver side central locking lock unit - F220-
❑ Removing and installing ⇒ General body repairs, exterior; Rep. gr. 57 ; Front door, door components,
central locking; Removing and installing front door lock
12 - Removing and installing central locking SAFELOCK function warning lamp - K133-
❑ In front door trim
13 - Driver door control unit - J386-
❑ In driver door
❑ Removing and installing ⇒ Glazing, window regulator; Rep. gr. 64 ; Removing and installing window
regulator motor
14 - Central locking and anti-theft alarm system aerial - R47-
❑ Behind A-pillar trim ⇒ page 402 .
11.2 Activating and deactivating anti-theft

alarm
Activating anti-theft alarm:
The anti-theft alarm is switched on automatically when the vehicle
is locked. The anti-theft alarm is then immediately primed.
Note
♦ To stop the anti-theft alarm system triggering an alarm unnec‐

essarily, close all windows and doors before locking vehicle.
♦ The anti-theft alarm cannot be activated if:
♦ Ignition terminal 15 is switched.

♦ The immobiliser detects an authorised key.
♦ The driver door is open.
♦ The door control unit is not OK
Deactivating anti-theft alarm:
♦ The anti-theft alarm is deactivated on unlocking the vehicle
with the remote control unlocking button or
♦ On opening the vehicle by way of the keyless access feature
or
♦ When the ignition terminal 15 is switched or
♦ When the immobiliser detects an authorised key.
Unlock the vehicle mechanically (emergency open).
– Unlock driver door using emergency key.

The anti-theft alarm system remains active, although no alarm is

triggered.
– Switch on ignition within 15 seconds.
Note
If you do not switch on the ignition, the alarm will trigger after 15
seconds.
When the ignition is switched on, the electronic immobiliser de‐

tects a valid ignition key and deactivates the anti-theft alarm.
11.3 Interior monitor deactivation switch -

E267- and deactivation button for vehi‐
cle inclination sender - E360-
– Removing and installing interior monitoring deactivation
switch - E267- and deactivation button for vehicle inclination
sender - E360- ⇒ page 348 .
11.4 Interior monitoring sensor - G273-

The interior monitor send and receive module 1 - G303- , the ve‐
hicle inclination sender - G384- and the interior monitoring sensor
- G273- (3 sensors) comprise one unit.
The interior monitoring sensor - G273- consists of three individual
sensors which are connected via wiring to the interior monitor
send and receive module 1 - G303- .
The interior monitoring sensors cannot be renewed individually.
11.5 Interior monitor send and receive mod‐

ule 1 - G303-
Note
11.5.1 Removing and installing interior monitor

send and receive module 1 - G303-

Note

Removing:
– Remove screws -1-, release locking lugs -arrows B- and re‐

move interior light from moulded headliner, as far as wiring
allows in direction of -arrow A-.
– Release connectors -1- and -2- and disconnect them.

– Unclip telephone microphone - R38- -arrow- on vehicles with
a hands-free system.
– Remove front interior light.

– Remove screws -arrows A-, release locking lugs -arrows B-

and remove console from moulded headliner in
-direction of arrow C-.
– Pull connector -2- off interior monitor send and receive module
1 - G303- -1-.
– Release interior monitor send and receive module 1 - G303-
-1- at fasteners -arrows-.
– Release fasteners of interior monitoring sensors and take in‐

terior monitoring sensors and interior monitor send and re‐
ceive module 1 - G303- out of moulded headliner.
11.6 Vehicle inclination sender - G384-

The vehicle inclination sender - G384- cannot be renewed sepa‐
rately.
11.7 Central locking and anti-theft alarm sys‐

tem aerial - R47-
The central locking and anti-theft alarm system aerial - R47- re‐
ceives the signals from the remote control and passes them to
the convenience system central control unit - J393- .
The central locking and anti-theft alarm system aerial - R47- con‐
sists of a RG174 HF wire where approx. 17 cm of the screening
is missing, this section is used as an aerial. The central locking
and anti-theft alarm system aerial - R47- is permanently attached
to the wiring harness and cannot be individually replaced. It is
located on the left A-pillar.

11.8 Adapting alarm delay on opening driver

door
This function can be used to switch the alarm delay on opening
the driver door on and off.
♦ Body
♦ Adapting alarm delay on opening driver door
11.9 Alarm horn - H12-

The alarm horn - H12- is located in the front right wheel housing.
11.9.1 Removing and installing alarm horn -

H12-
♦ Drill - VAS 5134-
♦ Twist drill bit ∅ 2.5 mm

♦ Twist drill bit ∅ 6 mm
Note
The anti-theft alarm must be deactivated ⇒ page 399 before re‐

moving the alarm horn.
Removing:
pairs, interior; Rep. gr. 66 ; Wheel housing liner; Removing
and installing front wheel housing liner; Removing .

– Use drill - VAS 5134- and a 6 mm ∅ twist drill bit to drill out the
shear-head bolts -arrows-.
– Release connector -1- by opening the cover -2- using a small

screwdriver and remove the alarm horn - H12- -3- from the
wheel housing.
– Use drill - VAS 5134- and a 2.5 mm ∅ twist drill bit to drill out
the remains of the bolts -arrows- and remove these using a
commercially available thread chaser.
Installing:
Note
Remove all metal swarf produced by drilling.
– Perform necessary corrosion protection measures ⇒ Body

Repairs; Rep. gr. Allgemeine Hinweise ; Body repairs .
– Connect connector to alarm horn - H12- .
Note
For reasons of clarity, the alarm horn - H12- is not shown in the
following illustration, therefore the connector is shown discon‐
nected.
– Guide clip -2- of alarm horn - H12- into aperture in body -1-.
– Secure alarm horn - H12- using shear-head bolts.
– Tighten shear-head bolts until bolt heads shear off.
– Install front right wheel housing liner ⇒ General body repairs,
interior; Rep. gr. 66 ; Wheel housing liner; Removing and in‐
stalling front wheel housing liner; Installing .

11.9.2 Checking alarm horn - H12-

The alarm horn - H12- can be checked using final control diag‐
nosis for convenience system central control unit - J393-
⇒ page 434 .

12 Taxi equipment
12.1 Onboard supply control unit - J519- for

special vehicles
Depending on equipment, different versions of the onboard sup‐
ply control unit - J519- for special vehicles are installed:
♦ Onboard supply control unit for medium special vehicles with‐
out heated windscreen
♦ Onboard supply control unit for high special vehicles without
heated windscreen
♦ Onboard supply control unit for medium special vehicles with
heated windscreen
♦ Onboard supply control unit for high special vehicles with
heated windscreen
12.1.1 Removing and installing onboard supply

control unit - J519- for special vehicles
Note
♦ The onboard supply control unit - J519- and relay carrier on

onboard supply control unit - J519- is one component and
cannot be renewed individually.
des stored in the “onboard supply control unit” if the onboard
supply control unit - J519- or the relay carrier are to be re‐
newed ⇒ page 423 .
Removing and installing onboard supply control unit for special

vehicles ⇒ page 423 .
12.2 Special vehicle control unit - J608-

The special vehicle control unit - J608- controls special equipment
and special functions in the following special vehicles:
♦ Taxis
♦ Driving schools
♦ Disabled
♦ Driving schools for the disabled
♦ Special signal vehicle
♦ Special armoured vehicle
The special vehicle control unit - J608- is equipped with self-di‐

12.2.1 Removing and installing special vehicle

Removing and installing special vehicle control unit - J608-
⇒ page 445 .
12.2.2 Coding special vehicle control unit -

J608-
Coding special vehicle control unit - J608- ⇒ page 446 .
12.2.3 Special vehicle control unit - J608- final

control diagnosis
Special vehicle control unit - J608- final control diagnosis
⇒ page 446 .
12. Taxi equipment 407

13 Specified torques: lights, bulbs and

switches - interior
13.1 Torque settings: alarm horn - H12-

Self-locking securing nut 5 Nm
Shear-head bolts 7 Nm
13.2 Specified torques: treble horn - H2-

Bracket securing bolts to longitudinal mem‐ M6 20 Nm
ber
13.3 Specified torques: bass horn - H7-

Bracket securing bolts to longitudinal mem‐ M6 20 Nm
ber

97 – Wiring
1 Vehicle diagnosis, testing and infor‐
mation systems
1. Vehicle diagnosis, testing and information systems 409

2 Fuse holder
Caution

served ⇒ page 4 .
2.1 Removing and installing fuse holder
Note
♦ The Passat is fitted with two fuse holders, one each on the left
and right of the dash panel.
♦ The following illustrations show the procedure for “Removing
left fuse holder”. The procedure for removing the right fuse
holder is analogue.

Caution

served ⇒ page 4 .
Removing:
410 Rep. gr.97 - Wiring

– Remove side cover -1- of dash panel by inserting removal

wedge - VAS 3409- or a suitable screwdriver in recess -2- and
levering off side cover -1- in direction of -arrow-.
– Remove securing screws -arrows- and remove fuse holder

-1- as far as wiring allows.
Installing:
– Tighten all securing bolts to specified torque ⇒ page 448 .
2. Fuse holder 411

3 Relay carriers
3.1 Removing and installing relay carrier on

left of dash panel
Caution

served ⇒ page 4 .
Removing:
– Remove dash panel ⇒ General body repairs, interior; Rep. gr.
70 ; Dash panel; Removing and installing dash panel.
– Pull relays -arrows- out of relay carrier.
Note
The number of relays and fuses depends on the vehicle equip‐

ment level.
– Unclip locking lugs in direction of -arrow- outwards and then

push connectors -1- through relay carrier.
– Release retainer -arrow A- and pull retainer with fuses in di‐

rection of -arrow B- off of relay carrier.

– Release locking lugs in direction of -arrows- and pull thermal

fuses -1- out of holders.
– Release locking lug -1- in direction of -arrow A- and pull holder

in direction of -arrow C- off of relay carrier.
– Release locking lug -2- in direction of -arrow B- and pull holder
in direction of -arrow C- off of relay carrier.
– Release locking lug -1- of relay carrier in direction of -arrow-

and take out relay carrier.
Installing:
– First unclip the connector (for relays), the holder (for fuses)
and the holder (for thermal fuses) in the relay carrier.
– Seat relay carrier -2- in guide -1- and clip relay carrier in place.
3. Relay carriers 413

3.2 Removing and installing onboard supply

Note

Removing:
– Remove cover in footwell on driver side ⇒ General body re‐
pairs, interior; Rep. gr. 68 ; Compartments, covers and trim;
Removing and installing footwell cover on driver side .
– Push locking catch -1- of relay carrier connector on onboard
supply control unit - J519- in -direction of arrow-.
Note
♦ The relay carrier connector on onboard supply control unit -

J519- can only be pulled off after moving the locking catch to
the “OPEN” position.
♦ The number of connectors and therefore the number of relays
depends on the vehicle equipment level.
♦ All connectors can only be fitted in one position and do not
therefore have to be marked.
– Push locking catch -1- of onboard supply control unit connec‐

tor in direction of -arrow-.
Note
♦ The onboard supply control unit connectors can only be pulled

off after the locking catch has been moved to the “OPEN” po‐
sition.
♦ The number of connectors on onboard supply control unit -
J519- depends on the vehicle equipment level.

– Unclip onboard supply control unit - J519- and relay carrier on

onboard supply control unit out of retainers -arrows-.
– Pull onboard supply control unit - J519- and relay carrier on
onboard supply control unit downwards and to rear out of
holder.
Installing:
Note
The locking catches cannot be placed in the “CLOSED” position

until all connectors are “fitted” correctly.
3. Relay carriers 415

4 Electronics boxes
4.1 Removing and installing E-box on left

side of engine compartment
Caution

served ⇒ page 4 .
Removing:
– Push safety clip -1- in direction of -arrow- and remove cover
from E-box -2- upwards.
– Remove hexagon nuts -1-.

– Open -arrows- covers -2- of cable guides on E-box.
– Remove wiring from stud connections.
– Unclip wiring from cable guides.

– Remove central bolt -arrow- from E-box -1-.
Note
When the central bolt -arrow- is removed, the E-box -1- is pushed
upwards off the E-box holder.
– Pull E-box -1- upwards off bracket of E-box.
Note
For removal of the flat contact housing -1-, the air filter housing
(on vehicles with diesel engine only), the battery and the battery
carrier must be removed.
– If necessary, remove air filter housing.

– Remove battery ⇒ page 4 .
– Remove securing bolts -arrows- from battery carrier -1-.

– Take battery carrier -1- out of vehicle.
4. Electronics boxes 417

– Press tabs apart on retainer of E-box -arrows B- and slide flat

contact housing -1- sideways -arrow A- out of retainer of E-
box.
– Press tabs apart on bracket of E-box -arrows C- and slide flat
contact housing -2- forwards -arrow D- out of bracket of E-box.
– Remove securing nuts -arrows- from bracket of E-box -1-.
Note
The installation of an additional relay carrier depends entirely on

the vehicle equipment.
– Pull retainer of E-box -1- upwards off studs (as far as cables
of additional relay carrier allow).
– Unclip additional relay carrier -1- sideways out of retainer of

E-box -2-.
– Take bracket of E-box -2- out of vehicle.
Installing:
– Tighten securing bolts or securing nuts to specified torques
⇒ page 448 .

– Mount cover -2- on E-box and push safety clip -1- in direction
of -arrow- until cover -2- engages.
Note
Then check whether the cover -2- of the E-box is engaged cor‐
rectly.
4. Electronics boxes 419

5 Main fuse box

A main fuse box is installed in vehicles with a battery in the lug‐
gage compartment; which also contains the pyrotechnic battery
isolator.
WARNING

Note

tions
5.1 Removing and installing main fuse hold‐

er
The main fuse box is located in the luggage compartment above
the battery behind the left wheel housing.
Removing:
– Remove pyrotechnical battery isolator ⇒ page 22 .

– Remove securing nuts -3-, -4- and -5- and remove wiring from
connector threads.
– Pull connector -1- out of retainer in main fuse box.

– Pull locking tab -1- outwards in direction of arrow and discon‐

nect connector -2-.
– Unscrew both securing bolts -arrows- and remove main fuse

box -1- from vehicle.
Installing:
⇒ page 21 .
5. Main fuse box 421

6 Control units
6.1 Onboard supply control unit - J519-
Note


System
tions
The onboard supply control unit - J519- is responsible for the fol‐
lowing in the vehicle:
♦ Electrical load management
♦ Exterior light control
♦ Turn signal control
♦ Rear window wiper
♦ Heated rear window
♦ Interior light control
♦ Ambient lighting
♦ Terminal control
♦ Dimmers, instrument lighting
♦ Fuel pump presupply
♦ Alternator stand-by
♦ Horn
The following functions can be adapted:
♦ Adaption of main beam for driving light assist ⇒ page 425
♦ Adaption of delay for driving light assist ⇒ page 425
♦ Adapting footwell light dimmer value ⇒ page 426
♦ Adjustment of coming home time ⇒ page 426
♦ Adjustment of leaving home time ⇒ page 426
♦ Adjustment of “active time” (headlight cleaning time) of head‐
light washer system ⇒ page 427
♦ Adapting heater “switch-off time” for rear window and exterior
mirrors ⇒ page 427

Note
It depends on the fitted optional equipment whether or not the

above-mentioned adaptations can be carried out.

6.1.1 Removing and installing onboard supply

Note

Removing:
– Removing onboard supply control unit - J519- or relay carrier
on onboard supply control unit - J519- ⇒ page 414 .
Installing:
– Installing onboard supply control unit - J519- or relay carrier
on onboard supply control unit - J519- ⇒ page 414 .
6.1.2 Coding onboard supply control unit -

J519-
♦ Body
♦ Functions
♦ Coding control unit
6. Control units 423

6.1.3 Onboard supply control unit - J519- final

control diagnosis
Note
Whether the components named below can be checked depends

on the fitted equipment options.
The following components and/or functions can be checked by

the final control diagnosis for the onboard control unit:
♦ Left sidelight bulb - M1- , Right sidelight bulb - M3- , Left tail
light bulb - M4- and Right tail light bulb - M2-
♦ Left headlight dipped beam bulb - M29- and right headlight
dipped beam bulb - M31-
♦ Left headlight main beam bulb - M30- and right headlight main
beam bulb - M32-
♦ Left dip beam screen motor - V294- and right dip beam screen
motor - V295-
♦ Left fog light bulb - L22- and right fog light bulb - L23-
♦ Right reversing light bulb - M17-
♦ Left brake light bulb - M9- or right brake light bulb - M10- and
high-level brake light bulb - M25-
♦ Left rear fog light bulb - L46-
♦ Number plate light - X-
♦ Front left turn signal bulb - M5- , driver side exterior mirror turn
signal bulb - L131- and rear left turn signal bulb - M6-
♦ Front right turn signal bulb - M7- , front passenger side exterior
mirror turn signal bulb - L132- and rear right turn signal bulb -
M8-
♦ Left footwell light - W9- and right footwell light - W10-
♦ Dimmed interior light
♦ Instrument lighting of all keys and switches and the dash panel
insert
♦ Terminal 30 voltage supply relay - J317-
♦ LED heated rear window / heated rear window
♦ LED heated exterior mirrors / heated exterior mirrors
♦ Release of sliding/tilting sunroof
♦ Release of seat heating
♦ Fuel pump relay - J17-
♦ Headlight washer system relay - J39- and headlight washer
system pump - V11-
♦ Windscreen wipers
♦ Wiper module change direction point
♦ Windscreen and rear window washer pump - V59- , front
♦ Windscreen and rear window washer pump - V59- , rear
♦ Dual tone horn relay - J4- , treble horn - H2- and bass horn -
H7-


♦ Body
♦ Functions
♦ Onboard supply control unit final control diagnosis
6.1.4 Adapting main beam for driving light as‐

sist
Note
♦ When the driving light assist (DLA) or the automatic headlight

control (AHC) is switched on the driving lights are automati‐
cally switched on or off by the twilight sensor and/or the rain
sensor.
This driving lights can be switched on or off by the driving light
assist system.
♦ Body
♦ Functions
♦ Adapting main beam for driving light assist
6.1.5 Adapting delay for driving light assist
Note
♦ When the driving light assist (DLA) or the automatic headlight

control (AHC) is switched on the driving lights are automati‐
cally switched on or off by the twilight sensor and/or the rain
sensor.
The delay for switching the driving light assist on or off can be set
to between 0 and 255 seconds.


♦ Body
♦ Functions
♦ Adapting main beam for driving light assist
6.1.6 Adapting footwell light dimmer value

The footwell lighting dimmer can be adjusted at various levels.
♦ Body
♦ Functions
♦ Adapting footwell light dimmer value
6.1.7 Adapting coming home time

Coming home: duration of lighting time on leaving the vehicle.
The lighting time of the coming home function can be adjusted
between 0 and 120 seconds.
♦ Body
♦ Functions
♦ Adapting coming home time
6.1.8 Adapting leaving home time

Leaving home: duration of lighting time on opening the vehicle.
The lighting time of the leaving home function can be adjusted
between 0 and 120 seconds.

♦ Body
♦ Functions
♦ Adapting leaving home time
6.1.9 Adapting headlight washer system

The “active time” (headlight cleaning time) of the headlight washer
system can be adjusted between 0 and 12.75 seconds.
♦ Body
♦ Functions
♦ Adapting headlight washer system
6.1.10 Adapting heater switch-off time for rear

window and exterior mirrors
The heating time of the heated exterior mirrors can be adjusted
from between 1 and 255 minutes.
Note
The adaption can only be carried out on vehicle with base level
of equipment.

♦ Body
♦ Functions
♦ Adapting heater switch-off time for exterior mirrors
6.2 Data bus diagnostic interface - J533-
Note


System
tions
The data bus diagnostic interface - J533- (Gateway) is designed
as a separate control unit. It is responsible for the following in the
vehicle:
♦ Exchange of data between the CAN data bus systems “drive‐
train CAN data bus”, “convenience CAN data bus” and “info‐
tainment CAN data bus”.
♦ Conversion of diagnostic data from CAN data bus systems to
K-wire and visa versa, so that the data can be used by the
vehicle diagnosis tester .
Note
If the data bus diagnostic interface - J533- is to be replaced, it is

essential that the procedure for replacing the “data bus diagnostic
interface -J533” is carried out, so that the codes stored in the unit
can be read ⇒ page 428 .
It is possible to check to see if the individual drive busses (pow‐

ertrain, convenience and infotainment) have changed to the sleep
mode ⇒ page 429 .
Furthermore, it is possible to check the status of the connection
from the data bus diagnostic interface - J533- to another bus sub‐
scriber.
The data bus diagnostic interface - J533- is equipped with self-
diagnosis, which is designed to simplify fault finding.
6.2.1 Renewing data bus diagnostic interface

- J533-
♦ Body
♦ Data bus diagnostic interface
♦ Data bus diagnostic interface functions
♦ Renewing data bus diagnostic interface
– Removing and installing data bus diagnostic interface - J533-
⇒ page 429 .

6.2.2 Removing and installing data bus diag‐

nostic interface - J533-
Removing:
Note
If the diagnosis interface for data bus - J533- is to be replaced,

the
⇒ “6.2.1 Renewing data bus diagnostic interface J533 ”,
page 428 procedure must always be carried out for reading the
codes stored in the unit.

– Remove cover in footwell on driver side ⇒ General body re‐
pairs, interior; Rep. gr. 68 ; Compartments, covers and trim;
Removing and installing footwell cover on driver side .
– Release and disconnect connector -1- from data bus diagnos‐
tic interface - J533- -2-.
– Press securing pins -3- together -arrows- and push out of
holes.
– Remove data bus diagnostic interface - J533- from vehicle.
Installing:
6.2.3 Checking bus activity

Using this test it is possible to check to see if the individual drive
busses (powertrain, convenience and infotainment) have
changed to the sleep mode.
♦ Body
♦ Checking bus activity
6.2.4 Checking bus participants

Using this test it is possible to check the status of the connection
from the data bus diagnostic interface to another bus participant.

♦ Body
♦ Checking bus participants
6.3 Convenience system central control unit

- J393-
Depending on equipment, the following control units are integra‐
ted into the convenience system central control unit - J393- :
♦ Immobiliser control unit - J362- or entry and start authorisation
♦ Tyre pressure monitor control unit - J502-
System
tions
The convenience system central control unit - J393- is, depending
on equipment, responsible for the following in the vehicle:
♦ Control of the central locking system
♦ Activation of the rear door control unit
♦ Activation of the rear lid unlocking function
♦ Activation of the fuel filler flap unlocking function
♦ Activation of the anti-theft alarm (ATA), further information
⇒ page 397
♦ Activation of the immobiliser, further information ⇒ page 389
♦ Activation of the entry and start authorisation system, further
information ⇒ page 319
♦ Activation of the tyre pressure monitoring system, further in‐
formation ⇒ Running gear, axles, steering; Rep. gr. 44 .

Note
equipment.
Further functions (convenience system) can be adapted after

connecting a vehicle diagnosis tester. Then select the operating
mode “Guided fault finding”, select key “GoTo”, select key “Func‐
tions/operating mode” and select the menu positions “Body”,
“General Body Repairs”, “01 - On Board Diagnostic capable sys‐
tems”, “Convenience systems” and “Functions - Convenience
system central control unit”:
♦ Deactivating “factory mode”.
♦ Adapting “Unlocking of individual doors”
♦ Adapting “Automatic locking”
♦ Adapting “Automatic unlocking on removing ignition key”
♦ Adapting “Feedback for unlocking via access and start au‐
thorisation”
♦ Adapting “Feedback for unlocking via remote control”
♦ Adapting “Feedback for unlocking via key switch”
♦ Adapting “Feedback for locking via access and start authori‐
sation”
♦ Adapting “Feedback for locking via remote control”
♦ Adapting “Feedback for locking via key switch”
♦ Adapting “Feedback for anti-theft alarm system armed”
♦ Adapting “Country setting for intelligent alarm horn”
♦ Adapting “sensitivity of inclination sensor”.
♦ Adapting “Sensitivity of interior monitoring system”
♦ Adapting “battery monitoring system (sounder)”.
♦ Adapting “Convenience operation via remote control”
♦ Adapting “Anti-theft alarm delay on opening driver door”
The control unit for convenience system - J393- is equipped with
self-diagnosis, which makes fault finding easier.

6.3.1 Removing and installing convenience

Note
equipment.
Removing:
– Remove glove compartment ⇒ General body repairs, interior;
installing glove compartment .
– Pull locking lug -2- of retainer for convenience system central
control unit - J393- in -direction of arrow- and push conven‐
ience system central control unit - J393- until recesses -1- are
positioned over recesses -3-.

Note
The connectors can only be released and disconnected once the

recesses -arrows- of the connector and bracket are aligned with
each other precisely.
– Release connector and pull connector off central convenience

system control unit - J393- .
Note
♦ The number of connectors depends on the vehicle equipment

level.
– Remove securing nuts -arrows-.

– Remove bracket with convenience system central control unit
- J393- -1-.
– Pull locking lug -1- in -direction of arrow B- and push conven‐

ience system central control unit - J393- -2- in
-direction of arrow A- out of bracket -3-.
Installing:
– Tighten all securing nuts to specified torque ⇒ page 448 .
Note
The connectors can only be pushed on and locked once the re‐
cesses -arrows- of the connector and bracket are aligned with
each other precisely.

6.3.2 Renewing and/or coding convenience

♦ Body
♦ Renewing/coding J393 - convenience system central control
unit
Note

equipment.
6.3.3 Convenience system central control unit

- J393- final control diagnosis
Note
It depends on the fitted equipment options as to whether the sub‐

sequently mentioned components and /or functions can be
checked.
The following components and functions can be checked by the

unit - J393- :
♦ Rear left entry light - W33-
♦ Rear left central locking lock unit - F222- (central locking for
the rear left door will be activated)
♦ Rear right entry light - W34-
♦ Rear right central locking lock unit - F223- (central locking for
the rear right door will be activated)
♦ Activation of fuel tank filler flap (fuel tank filler flap will be
opened)
♦ Activation of rear lid (rear lid will be opened)
♦ Vehicle inclination sender warning lamp - K188- (LED) in de‐
activation switch for vehicle inclination sender - E267-
♦ Interior monitoring off warning lamp - K162- (LED) in deacti‐
vation switch for vehicle inclination sender - E360-

♦ Alarm horn - H12-

♦ Body
♦ J393 - convenience system central control unit - final control
diagnosis
6.3.4 Reading alarm sources of anti-theft

alarm
Once the anti-theft alarm system has been triggered the source
of the alarm can be read (i.e. vehicle inclination sender - G384-
or).
♦ Body
♦ Reading J393 alarm sources of anti-theft alarm
6.3.5 Reading alarm sources of alarm horn

Once the anti-theft alarm has been triggered, the alarm source
can be read (i.e. vehicle battery monitor or alarm triggered by
convenience system control unit).
♦ Body
♦ J393 - Reading sources of the alarm for alarm horn

6.4 Driver door control unit - J386-
Note
♦ The driver door control unit - J386- and the driver side window
regulator motor - V147- are contained in one unit and cannot
be replaced individually.
♦ If the driver door control unit - J386- or the driver side window
regulator motor - V147- are replaced, then the work procedure
“Coding driver door control unit” must be subsequently per‐
formed ⇒ page 436 .

System
tions
6.4.1 Removing and installing driver door con‐

trol unit - J386-
Removing and installing driver door control unit - J386- ⇒ General
body repairs, exterior; Rep. gr. 64 ; Front door window; Removing
and installing window regulator motor .
Note
If the driver door control unit - J386- or the driver side window
“Coding driver door control unit” must be subsequently performed
⇒ page 436 .
6.4.2 Coding driver door control unit - J386-

♦ Body
♦ Driver door electronics
♦ Functions of driver door control unit
♦ Coding J386 - driver door control unit

6.4.3 Driver door control unit - J386- final con‐

trol diagnosis
Note

checked.

the final control diagnosis for the door control unit:
♦ Activation of driver side switch illumination
♦ Activation of driver side central locking (activating)
♦ Activation of driver side mirror functions (mirror heater and
mirror folding functions)
♦ Activation of turn signal in driver side exterior mirror ( driver
side exterior mirror turn signal bulb - L131- )
♦ Activation of driver side ambient lighting ( driver side entry light
in exterior mirror - W52- )
♦ Activation of driver side electric window (lowering)
♦ Activation of driver side electric window (raising)
♦ Body
♦ Driver door electronics
♦ Functions of driver door control unit
♦ J386 - driver door control unit, final control diagnosis
6.5 Front passenger door control unit -

J387-
Note
♦ The front passenger door control unit - J387- and the front
passenger side window regulator motor - V148- are contained
in one unit and cannot be replaced individually.
♦ If the front passenger door control unit - J387- or the front
passenger side window regulator motor - V148- are replaced,
then the work procedure “Coding front passenger door control
unit” must be subsequently performed ⇒ page 438 .

System


tions
6.5.1 Removing and installing front passenger

door control unit - J387-
Removing and installing front passenger door control unit - J387-
⇒ General body repairs, exterior; Rep. gr. 64 ; Front door window;
Removing and installing window regulator motor .
Note
If the front passenger door control unit - J387- or the front pas‐
senger side window regulator motor - V148- are replaced, then
the work procedure “Coding front passenger door control unit”
must be subsequently performed ⇒ page 438 .
6.5.2 Coding front passenger door control unit

- J387-
♦ Body
♦ Front passenger door electronics
♦ Functions of front passenger door control unit
♦ Coding J387 - front passenger door control unit
6.5.3 Front passenger door control unit -

J387- final control diagnosis
Note

checked.

♦ Activation of front passenger side switch illumination
♦ Activation of front passenger side central locking (activating)
♦ Activation of front passenger side mirror functions (mirror
heater and mirror folding functions)
♦ Activation of turn signal in front passenger side exterior mirror
( front passenger side exterior mirror turn signal bulb - L132- )
♦ Activation of front passenger side ambient lighting ( front pas‐
senger side entry light in exterior mirror - W53- )
♦ Activation of front passenger side electric window (lowering)
♦ Activation of front passenger side electric window (raising)


♦ Body
♦ Front passenger door electronics
♦ Functions of front passenger door control unit
♦ J387 - front passenger door control unit, final control diagnosis
6.6 Coding rear left door control unit - J388-
Note
♦ The rear left door control unit - J388- and the rear left window
regulator motor - V26- are contained in one unit and cannot
be replaced individually.
♦ If the rear left door control unit - J388- or the rear left window
“Coding rear left door control unit” must be subsequently per‐

System
tions
6.6.1 Removing and installing rear left door

Removing and installing rear left door control unit - J388- ⇒ Gen‐
eral body repairs, exterior; Rep. gr. 64 ; Rear door window;
Note
If the rear left door control unit - J388- or the rear left window
“Coding rear left door control unit” must be subsequently per‐
6.6.2 Coding rear left door control unit - J388-

♦ Body


♦ Rear left door electronics
♦ Function of rear left door control unit
♦ Coding J388 - rear left door control unit
6.6.3 Rear left door control unit - J388- final

control diagnosis
Note

checked.

♦ Activation of rear left door switch illumination.
♦ Activation of rear left electric window (lowering)
♦ Activation of rear left electric window (raising)
♦ Body
♦ Rear left door electronics
♦ Function of rear left door control unit
♦ J388 - rear left door control unit, final control diagnosis
6.7 Coding rear right door control unit -

J389-
Note
♦ The rear right door control unit - J389- and the rear right win‐
dow regulator motor - V27- are contained in one unit and
cannot be replaced individually.
♦ If the rear right door control unit - J389- or the rear right window
“Coding rear right door control unit” must be subsequently
performed ⇒ page 441 .

System
tions

6.7.1 Removing and installing rear right door

Removing and installing rear right door control unit - J389- ⇒
General body repairs, exterior; Rep. gr. 64 ; Rear door window;
Note
If the rear right door control unit - J389- or the rear right window
“Coding rear right door control unit” must be subsequently per‐
6.7.2 Coding rear right door control unit -

J389-
♦ Body
♦ Rear right door electronics
♦ Functions of rear right door control unit
♦ Coding J389 - rear right door control unit
6.7.3 Rear right door control unit - J389- final

control diagnosis
Note

checked.

♦ Activation of rear right door switch illumination.
♦ Activation of rear right electric window (lowering)
♦ Activation of rear right electric window (raising)
♦ Body
♦ Rear right door electronics

♦ Functions of rear right door control unit

♦ J389 - rear right door control unit, final control diagnosis
6.8 Trailer detector control unit - J345-

The trailer detector control unit - J345- -arrow- is located behind
the side trim at the rear left of the luggage compartment.
Note

tions
Note
♦ The Passat is only fitted at present with Westfalia control units.

♦ Use is to be made for checking the control unit of the socket
tester - V.A.G 1537/A-
⇒ “6.8.3 Trailer detector control unit J345 final control diag‐
nosis”, page 444 .
The trailer detector control unit - J345- detects from a power draw
of minimum 5 W13) the “trailer operation” and transmits this infor‐
mation to various control units via the CAN data bus.
The trailer detector control unit - J345- is supplied with information
(light control) from the onboard supply control unit - J519- and
convenience system central control unit - J393- via the CAN.
13) “Trailer operation” can only be detected if at least turn signal indicators or side
marker lights are switched on.

The trailer detector control unit - J345- features self-diagnosis to
facilitate fault finding.
6.8.1 Removing and installing trailer detector


Removing:
– Remove left side wall trim in luggage compartment ⇒ General
body repairs, interior; Rep. gr. 70 ; Load and luggage com‐
partment trim; Removing and installing luggage compartment
side trim .
– Release connectors -2- and disconnect them from trailer de‐
tector control unit - J345- .
Note
The number of connectors at the trailer detector control unit -

J345- may differ from the illustration, depending on vehicle equip‐
ment.
– Remove securing bolts -1- and take trailer detector control unit
- J345- with bracket out of vehicle.
– Remove securing bolts -arrows- and detach trailer detector

control unit - J345- from bracket.
Installing:
Note
Following installation, a new trailer detector control unit - J345-

must be encoded ⇒ page 443 .
6.8.2 Coding trailer detector control unit -

J345-
♦ Body
♦ Trailer detector
♦ Functions
♦ Coding trailer detector control unit

6.8.3 Trailer detector control unit - J345- final

control diagnosis
Note
♦ The trailer detector control unit - J345- only detects “Trailer

operation” as of a power decrease of at least 5 W13).
♦ Use is to be made for checking of the socket tester - V.A.G
1537/A- .

♦ Socket tester - V.A.G 1537/A- 14)
14) The socket tester - V.A.G 1537/A- will become too warm after some minutes
of use and will switch itself off. The socket tester - V.A.G 1537/A- will function
again without problem after it has cooled down.
– Connect socket tester - V.A.G 1537/A- .

♦ Body
♦ Trailer detector
♦ Functions
♦ Trailer detector control unit - final control diagnosis
6.9 Special vehicle control unit - J608-

The special vehicle control unit - J608- controls special equipment
and special functions in the following special vehicles:
♦ Taxis
♦ Driving schools
♦ Disabled
♦ Driving schools for the disabled
♦ Special signal vehicle
♦ Special armoured vehicle


The special vehicle control unit - J608- is equipped with self-di‐
6.9.1 Removing and installing special vehicle

The special vehicle control unit - J608- is located in the floor area
beneath the driver seat:
Removing:
– Remove driver seat ⇒ General body repairs, interior; Rep. gr.
72 ; Front seats; Removing and installing front seat .
– Release connector -2- and pull off special-purpose vehicle
control unit - J608- -1-.

– Unscrew four securing bolts -1- and remove special vehicle

control unit - J608- -2- upwards from vehicle.
Installing:
Note
When installing special vehicle control unit - J608- , ensure that

surrounding cables are not crushed!
– First install special vehicle control unit - J608- on its bracket

with four securing bolts.
– Then position and lock the connector.
– Tighten all securing nuts to specified torque ⇒ page 448 .
6.9.2 Coding special vehicle control unit -

J608-
♦ Body
♦ Special vehicle control unit
♦ Functions
♦ Coding the multifunction control unit
6.9.3 Special vehicle control unit - J608- final

control diagnosis
Note
Whether the components or functions mentioned below can be

checked depends on the equipment fitted.
The following components and functions can be checked via final

control diagnosis for the special vehicle control unit - J608- :
♦ Terminal 15
♦ Speed signal
♦ Roof symbol illumination
♦ Roof symbol alarm
♦ Battery isolation relay J7
♦ Front and rear window lifter actuation
♦ Smoke extractor
♦ Intercom system
♦ Main radio activation

♦ Siren
♦ Priority vehicle warning light
♦ Body
♦ Special vehicle control unit
♦ Functions
♦ Special vehicle control unit final control diagnosis
6.10 Electronic steering column lock (ESL)

Steering column lock control element - J764- is integrated into
electronic steering column lock control unit - N360- . Steering col‐
umn lock control element - N360- cannot be renewed separately.
Note
♦ Electronic steering column lock control unit - J764- is secured

to steering column with shear bolts, and may only be renewed
together with the entire steering column.
♦ All information on further procedure can be obtained via vehi‐
cle diagnosis tester .
♦ If the electronic steering column lock control unit - J764- is to
be renewed, the procedure for “adapting the electronic steer‐
ing column lock control unit” must always be carried out be‐
forehand ⇒ page 394 .
6.10.1 Removing and installing electronic

steering column lock control unit - J764-
Removing and installing electronic steering column lock control
unit - J764- ⇒ page 392 .
6.10.2 Adapting electronic steering column

Adapting electronic steering column lock control unit - J764-
⇒ page 394 .
6.10.3 Checking electronic steering column

Checking electronic steering column lock control unit - J764-
⇒ page 394 .

7 Specified torques: wiring
7.1 Specified torques: fuse holder

Securing bolts 4 Nm
7.2 Specified torques: E-box on left side of

engine compartment
Securing nuts -1- M5 (8 mm) 4 Nm
Securing nuts -1- M6 (10 mm) 6 Nm
Electronics box central 9 Nm
bolt
7.3 Specified torques: convenience system

central control unit - J393-
Securing nuts 4.5 Nm
7.4 Specified torques: special vehicle con‐

trol unit - J608-
Securing bolts 6 Nm

8 Wiring harness and connector re‐

pairs
8. Wiring harness and connector repairs 449

VW Passat b6 Electrical System Diagram

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Service

Service Department. Technical Information

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Copyright © 2015 Volkswagen AG, Wolfsburg K0059020020

27 - Starter, current supply, CCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

90 - Gauges, instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

92 - Windscreen wash/wipe system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

4.1 Assembly overview - rear window washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

94 - Lights, bulbs, switches - exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

4.1 Removing and installing front turn signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248

13.5 Park assist steering button E581 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316

96 - Lights, bulbs, switches - interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348

5 Lights and switches in rear doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369

2.1 Removing and installing fuse holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410

27 – Starter, current supply, CCS

Danger of injury! Observe warning notices and safety regula‐

To prevent damage to the battery and vehicle, the following

1.1 Fundamentals for batteries

1.2 Types of battery

1.3 Warning notices and safety regulations

1.4 Battery terminal connection

2 Rep. gr.27 - Starter, current supply, CCS

4 Disconnecting and reconnecting bat‐

Danger of injury! Observe warning notices and safety regula‐

The following vehicle battery combinations may be installed de‐

3.2 l and 3.6 l V6 pet‐ Battery

4.1 Disconnecting and connecting battery,

♦ Disconnecting the battery involves deactivating the anti-theft

4.1.1 Disconnecting battery

4 Rep. gr.27 - Starter, current supply, CCS

– Release catch -arrow- and take cover off battery housing.

– Then unscrew battery positive terminal clamp -2- from battery

4.1.2 Reconnecting battery

Observe notes for battery terminal clamp bolt ⇒ page 1 .

Special tools and workshop equipment required

– Fit battery positive wire clamp -2- to battery positive terminal

4. Disconnecting and reconnecting battery 5

– Finally when window is

– Check convenience func‐

4.2 Disconnecting and reconnecting bat‐

♦ Disconnecting the battery involves deactivating the anti-theft

4.2.1 Disconnecting additional battery on left

6 Rep. gr.27 - Starter, current supply, CCS

– Release locking lug -arrow- and remove storage compart‐

– First unscrew battery earth terminal clamp -1- from battery

4. Disconnecting and reconnecting battery 7

4.2.2 Reconnecting additional battery on left

Observe notes for battery terminal clamp bolt ⇒ page 1 .

Special tools and workshop equipment required

– Fit battery positive wire clamp -2- to battery positive terminal

Positive wire battery clamp must be turned in direction of travel.

4.3 Disconnecting and reconnecting bat‐

8 Rep. gr.27 - Starter, current supply, CCS

♦ Disconnecting the battery involves deactivating the anti-theft

4.3.1 Disconnecting battery on left in luggage

4.3.2 Reconnecting battery on left in luggage

Observe notes for battery terminal clamp bolt ⇒ page 1 .

Special tools and workshop equipment required

– Fit battery positive wire clamp -2- to battery positive terminal